Auto-Zone Control Systems Auto-Zone Basic Systems User Manual

Design, Installation

Basic System

and Operations Manual

Revision 02C

Auto-Zone

Basic

Design, Installation & Operations Manual

Section 1..............................................................................System Overview

Section 2...................................................................Installation and Wiring

Section 3....................................................................................Programming

Section 4........................................................Start-Up and Troubleshooting

This document is subject to change without notice.

WattMaster Controls, Inc. assumes no responsibility

for errors, or omissions herein.

Auto-Zone Basic Installation & Operations Manual - Form WM-AZB-IO-02C

Auto-Zone is a registered trademark of WattMaster Controls, Inc.

Copyright 2009 WattMaster Controls, Inc.

All rights reserved.

Section 1

Table of Contents

Conventions .....................................................................1

General Information.........................................................3

Description of System Components.................................................................................3

Design Considerations.....................................................5

Zone Diversity .................................................................................................................5

Cooling - Partial Load Conditions ...................................................................................5

Heating - Partial Load Conditions ...................................................................................7

Override Conditions.........................................................................................................7

Building Pressurization....................................................................................................7

Design Guide....................................................................8

Step #1 - Zoning ..............................................................................................................8

Step #2 - Sizing the Central Unit ...................................................................................10

Step #3 - Duct Design Considerations...........................................................................10

Step #4 - Room Air Motion/Diffuser Selection.............................................................11

Step #5 - Bypass Damper Sizing ...................................................................................11

Step #6 - Sizing Zone Dampers .....................................................................................13

Round Dampers .............................................................................................................15

Rectangular Dampers.....................................................................................................15

Pressure Independent Zone Dampers ............................................................................16

Auxiliary Heat Control Options......................................17

Relay Expansion Board .................................................................................................18

Table of Figures & Tables

Figure 1-1: Auto-Zone Basic Control System...............................................................2

Figure 1-2: Control Zones Affected by the Outdoor Load ............................................9

Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control ............12

Figure 1-4: Round Damper Dimensions......................................................................14

Figure 1-5: Rectangular Damper & Kit Dimensions...................................................14

Table 1-1: Round Air Damper Selection .....................................................................15

Table 1-2: Rectangular Damper Selection...................................................................15

Table 1-3: Pressure Independent Flow Factors............................................................16

Design Guide

Auto-Zone Basic

Section 1

Conventions

This document uses the following definitions throughout as a guide to the user in
determining the nature of information presented:

Note: Additional information which may be helpful

Tip: Suggestion to make installation, set-up, and troubleshooting easier.

Caution: Items which may cause the equipment not to function correctly, but will

not otherwise damage components.

Warning: Errors which can result in damage to equipment and void warranties.

Design Guide 1-1

Section 1

A

V

Auto-Zone Basic

To HVAC Unit
Control Panel

Supply

ir Temp

Sensor

Optional Remote Li nk II

Connects to CommLink IV

And Provides Alarm Call-Outs

A Second Remote Link Is Required

If Connection To Job Site

Is Desired From Remote Computer

Remote Link II

(Optional)

CommLink IV

The CommLink IV Is

Required For All Systems.

The IP Module, Remote

Link II, And Computer Are

Optional On All Systems.

All Computers Requ ire

Installation of Prism

Graphical User Interface

Software

USB Cable To Computer

Phone Cable To
Telephone
Wall Outlet Jack

CommLink IV

Single Loop

Economizer

(Actuator By Others)

Outside

Air Temp

Sensor

Computer

(Optional)

24VAC

Ethernet Cable To Router

Ethernet Router

(By Others)

When IP Module

Option Is Used

RS-485

9600 Baud

Optional IP Module

Installs Into CommLink IV

And Provides
LAN And Internet
Communications

With The Control System

Static

Pressure

Sensor

Zone Controller

elocity Sensor

(Optional)

Return

Air Temp

Sensor

Bypass Air

Damper

Typical Zone

Damper Actuator

Zone Air Dampers

Up to 16 Zone Air Dampers Allowed

#1

Room Sensor

with Optional

Override & Adj.

#16

RS-485

Comm Loop

24 VAC

Figure 1-1: Auto-Zone Basic Control System

1-2 Design Guide

Auto-Zone Basic

Section 1

General Information

The primary application of the Auto-Zone Basic Control System is to provide multiple
controlled comfort zones from a single zone, unitary heating and air-conditioning
package unit. It can also be applied to existing installations for improved comfort to
multiple zones currently controlled by a single thermostat.

Description of System Components

A typical Auto-Zone Basic Control System is comprised of the following four basic
components.

Zone Manager

The Zone Manager is a microprocessor-based controller which monitors up to 16 zones

in the system. The zone manager then controls the HVAC unit to satisfy the requirements
of each individual zone while maintaining efficient operation and comfort. The zone
manager is also responsible for controlling duct static pressure.

In the Auto-Zone Basic version, the Zone Manager has a display and a keypad. The 4­line by 20-character display is backlighted, making it easier to read in low light
environments.

Bypass Damper

The bypass damper controls proper duct static pressure to insure proper airflow. The

damper is modulated by the Zone Manager based on a signal received from the static
pressure sensor connected to the main duct.

Zone Controller

The Zone Controller monitors space temperature and allocates proper airflow to the

assigned zone to achieve desired comfort and ventilation levels. If supply air temperature
will benefit the local zone temperature setpoint, the zone damper modulates to reduce or
increase airflow as needed. If supply air will not benefit the local zone, the controller will
direct the damper actuator to a minimum position and wait for a change in supply air
temperature.

Design Guide 1-3

Section 1

Auto-Zone Basic

Zone Sensor

The patented zone sensor is a flush, wall-mounted design. A special plate on the face of

the sensor accurately senses space conditions. As a result of its unique design, the zone
sensor rejects the influence of internal wall temperature effects. The sensor comes in four
different configurations:

• Sensor only

• Sensor w/push-button override (override is fixed at 2 hours)

• Sensor w/setpoint adjustment

• Sensor w/override & setpoint adjustment

Any combination of these sensor configurations can be used with the system.

1-4 Design Guide

Auto-Zone Basic

Section 1

Design Considerations

Consider the following items when designing a system using Auto-Zone.

Zone Diversity

The Auto-Zone Basic Control System is designed to improve tenant comfort by
dynamically re-balancing the air distribution when used with a typical constant volume
rooftop heating/cooling unit. If zones with extremely different load conditions are
serviced by a single rooftop unit, the result will be poor control and excessive wear due
to cycling of the equipment.

It is especially important to avoid mixing interior zones (which require cooling all year)
with exterior zones (which may require constant heat during winter months). If you must
mix zones under these conditions, consider using either VAV boxes with heat or separate
baseboard heat on exterior zones. Auto-Zone Basic Control Systems offer a variety of
methods to control additional zone heat to help you avoid problems.

Cooling - Partial Load Conditions

The engineer must be aware of several potential problems when applying the Auto-Zone
Basic Control System during cold weather operation.

Low Ambient Temperature Lockout

During very cold weather it is common for mechanical systems to have “low temp
lockouts” which protect equipment from damage if operated under these conditions.
Auto-Zone also provides user programmed lockouts for protection purposes, although

mechanical safeties should always be used as the final stage of protection.

If the rooftop unit services interior zones with thermal loads which require cooling when
outside temperatures are below the safe operating limits for your equipment, you should
seriously consider installing an economizer on your rooftop unit. The Auto-Zone control
system is designed to take advantage of an economizer if it is installed. The use of an
economizer will save money on utilities and provide comfort under conditions when it is
not possible to operate the mechanical cooling system.

Low Supply Air Temperatures

Under lightly loaded conditions much of the supply air may be bypassed back into the
return airside of the system. This bypassing will result in the lowering of the supply air

Design Guide 1-5

Section 1

temperature, which may result in the supply air temperature reaching the low temp safety
limit. If the supply air low temp safety limit is exceeded, the control system will “cut-off”
the mechanical cooling to protect it from damage. Excessive cycling of the mechanical
system will result if this condition persists. Comfort may also suffer if the system cannot
run long enough to satisfy cooling demands.

A number of things can be done to reduce this problem. Some of these things depend
upon the type of installation.

• Avoid oversizing the unit. Do your load calculations carefully. Since Auto-Zone

directs the heating or cooling to the zones which require it, you may find that you can
use a smaller unit in many cases. Oversizing is the number one cause of excessive
low supply air temperature cycling.

• Increase your cooling minimum airflow or damper position settings to allow more air

during cooling operation. Be careful to avoid settings which are so high you cause
over cooling of the spaces. Find a compromise position.

• Bypass the air into the plenum instead of into the return air intake. Be careful if you

use this method since you may get “dumping” of cold air from your return air grilles.
This method works best with plenum returns. Do not use this method with ducted
returns unless you have carefully considered the consequences.

• Increase your static pressure setpoint to help reduce the amount of air being bypassed.

Be aware of increased noise levels and the cost of operation if you use excessive
static pressures.

Auto-Zone Basic

Warning: If the fan system has the capability of producing static pressures

which could damage ductwork, you must provide a manual reset high
pressure limit switch to cut-off the fan system in the event of high
duct static. Do not use your Auto-Zone Basic Control System as a
safety device!

• Use an Economizer. Although this is not a cure-all, it greatly improves operation

during cool weather when cooling loads are minimal. Using an Economizer also
improves ventilation and lowers operating costs, both of which are significant.

1-6 Design Guide

Auto-Zone Basic

Section 1

Heating - Partial Load Conditions

Heating difficulties are less common than cooling difficulties. They are similar in nature,
however, and the cures are generally the same.

• Increase the Heating minimum setpoints on as many zones as possible.

• Increase the static pressure setting as high as is practical. Increasing static pressure

does not help if you are using pressure independent operation.

• Bypass to plenum instead of the return air intake if acceptable.

• Do not oversize your equipment.

• Use auxiliary heat in either your VAV boxes or baseboard.

Auto-Zone has a number of auxiliary heat control options which provide solutions to

most problems. Refer to the Auxiliary Heat Control Options topic near the end of this

section.

Override Conditions

After-hours overrides can produce aggravated partial load conditions in both the heating
and cooling modes. The problem is most commonly caused by a single zone being
overridden for after-hours use. This causes the rooftop equipment to operate for only one
zone. The Auto-Zone Basic Control System offers an improved solution to this common
problem by allowing a single override to trigger a group of zones via a “global” override.
This allows the system to operate with sufficient load to reduce cycling caused by light
load conditions.

Building Pressurization

If you are using an economizer, building pressurization must be addressed. Failure to
properly handle building pressurization may result in doors remaining open when the
economizer is operating. Pressurization problems can render economizer operation
useless. The following suggestions will help to avoid potential problems.

• Use powered exhaust when the system uses ducted returns. The return duct pressure

drop will cause most barometric relief dampers to function poorly or not at all. Auto­Zone has the ability to control a powered exhaust whenever the economizer is
operating.

• Use a separate building pressure control which operates a relief fan or dampers.

Design Guide 1-7

Section 1

Auto-Zone Basic

Design Guide

There are six basic steps to designing an Auto-Zone Basic Control System:

1. Zoning

2. Sizing the Central Unit

3. Duct Design Considerations

4. Room Air Motion / Diffuser Selection

5. Bypass Damper Sizing

6. Sizing Zone Dampers

Step #1 - Zoning

Determine the number of zones. A single air handler unit can have no more than 16
zones. If the number of zones exceeds 16, then more than one Zone Manager will be
required. Consider using the Auto-Zone Plus system if more than one Zone Manager is
required.

The primary precaution to be taken in applying the Auto-Zone Basic Control System is to
select the zoning so that no zone will be at maximum (design) heating (or cooling) load
when any other zone requires the opposite temperature air to satisfy its load. For
example, depending on the wall, ceiling, floor material, and location within the building
(e.g. top or middle floor), a typical floor of a building usually has a minimum of 9
distinct temperature or control zones that are affected uniquely by the outdoor load.

These zones are depicted in Figure 1-2.

Depending on the size of the building and partition layout, some of these zones may
overlap or be insignificant from a zoning standpoint. For example, Zone 10 could be
multiple conference or computer rooms where additional zoning would be required, or it
could be as small as a corridor where no zoning is required. Similarly, zones 4 and 5
could have no external windows and no partitions between them and could be considered
a single zone. Zone 3 could be divided into multiple offices with full partitions between
them, thus requiring separate Zone Controllers because of different internal loads, but the
same external load.

Generally, the greater the number of individual Zone Controllers there are, the greater the
comfort. The designer will have to look at the specific building, balancing the costs of
multiple zones with the added comfort possible with multiple zones, to match the owner's
requirements.

1-8 Design Guide

Auto-Zone Basic

Section 1

It is important to recognize that there are purely internal zones, such as Zone 10, which
may contain separate offices/conference/computer rooms. These internal zones could
easily have high cooling requirements while external zones (1, 2, 3, etc.) could be at or
near design heating load. This is a misapplication of the Auto-Zone Basic or Plus (or any
heating/cooling changeover) system. The interior zones with cooling-only loads should
be served with a separate air-conditioning unit (that could be zoned between multiple
rooms with a similar load profile). Supplemental heat could be added to the perimeter
zones and controlled with the auxiliary heat control board from the Zone Controller.
System performance will generally be compromised and frequent changeover from the
heating to the cooling mode will occur during the heating season if purely internal zones
are combined on the same air-conditioning unit serving perimeter zones.

Zoned HVAC Unit

Supply Air Duct

Supply Air Duct

9

Constant Volume HVAC Unit

Return Air Plenum

Bypass Damper

System Manager

Round Zone Damper
(Typical)

Room Sensor

(Typical)

W

S

Return Air Plenum

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Figure 1-2: Control Zones Affected by the Outdoor Load

Design Guide 1-9

Section 1

Auto-Zone Basic

Step #2 - Sizing the Central Unit

Because the zones are controlled with variable air volume, it is unlikely that all zones
will be at design load at the same time. The zoning allows for the diversity of loads to be
taken into account and will often provide better comfort with a smaller HVAC unit.

In sizing the system, the individual zone loads should be calculated using any dependable
load estimating program. Because of diversity, the central unit should be selected for the
instantaneous peak load, not the sum of the peak loads, as would be done with a constant
volume single zone system. Consider the following when sizing the central unit.

• Size the peak cooling load based on the month and hour of the greatest total

building/system load.

• Heating should be sized for the lowest design temperature with an additional margin

for morning "pickup." This margin is generally recommended to be 20 to 25 percent
of base design.

Step #3 - Duct Design Considerations

The Auto-Zone Basic Control System uses a typical low pressure duct design. To reduce
noise problems, duct pressures should not exceed 1 inch W.C.

Primary trunk ducts should not be "undersized." This is especially true for "pressure
dependent" systems. Pressure dependent refers to the typical Auto-Zone Zone Controller
without the airflow sensor. With larger trunk ducts, it is easier to assure relatively constant
pressure to each zone. Runs should be as short as possible and the trunk duct system kept
as symmetrical as possible to facilitate system balancing. Wherever possible, run the trunk
ducts above corridors and locate the zone dampers above corridors to reduce the noise in
the space and facilitate service of the units. Trunk ducts should be sized for no more than

0.1 inch W.C. drop per 100 feet and a maximum duct velocity of 2000 FPM.

Note: For pressure independent terminal units with velocity sensors and

conventional "VAV" boxes properly selected for "quiet" operation, this 2000
FPM rule can be exceeded by up to 50 percent. The designer, however, should
be very experienced in VAV system design before considering modification
of this general rule.

Typical VAV systems with pressure independent terminals use the static regain method
for sizing ducts. The typical Auto-Zone Basic Control System is a low-pressure, pressure
dependent system that utilizes conventional unitary air-conditioning units. These systems
should use the equal-friction method of sizing the ducts and use the maximum loss of 0.1
inch per 100 feet as described above.

1-10 Design Guide

Auto-Zone Basic

Section 1

Step #4 - Room Air Motion/Diffuser
Selection

Air motion is a consideration for occupant comfort. The selection of diffusers for an
Auto-Zone Basic Control System requires more care than a constant volume system due
to varying flow of air into the zones. Slot diffusers are recommended due to their superior
performance at low airflows. Because the zone airflow is variable volume, lower cost
round or rectangular diffusers that were satisfactory for constant volume may prove
unsatisfactory with an Auto-Zone Basic Control System. These diffusers may result in
"dumping" of the cold air at low flows in the cooling mode and insufficient room air
motion at low air flows in the heating mode. Although high air motion in the heating
mode can be undesirable, a slot diffuser with a high induction ratio generally helps to
reduce room air "stratification" when the heating comes from a ceiling diffuser. Linear
slot diffusers should be properly selected for the airflow and "throw" suited to the
specific installation or zone.

Additional factors to consider in diffuser selection are sound level and throw at design
flow. Generally, multiple diffusers will result in lower sound levels in the space, but this
must be balanced with the additional hardware and installation costs. It is commonly
recommended that slot diffusers be located near the perimeter or outside wall with the
airflow directed into the room. Consult your diffuser supplier or catalog for proper
diffuser sizing and location.

Series fan boxes may be used instead of zone dampers where higher induction rates are
desirable. If the heat loss on perimeter walls is high, such as large areas of glass, the use
of Series Fan Boxes may be indicated to maintain higher induction rates to offset
“downdrafts.” If the heat loss is greater than 275 BTUH/LINEAR FOOT, you should use
high quality slot diffusers next to the outer wall with the airflow directed inward to
counteract downdrafts during heating. Serious downdraft problems occur when heat
losses exceed 400 BTUH/LINEAR FOOT. In such case, both high induction diffusers
and series fan boxes are recommended.

Step #5 - Bypass Damper Sizing

Using a load calculation program, the bypass damper should be sized to give you the
maximum CFM of air to be bypassed, typically 60 to 70 percent of the HVAC units rated
capacity. Bypass Dampers can either be round or rectangular depending on building or
job requirements. Use the appropriate round or rectangular damper selection table to
determine the correct damper size for your application. To size the damper, select a
damper from the table based on calculated bypass CFM and a maximum velocity
between 1750-2250 FPM. When determining the bypass duct size, be sure to take into

account any transition fittings and associated pressure drops. (See Table 1-1: Round
Damper Selection or Table 1-2: Rectangular Damper Selection.)

Design Guide 1-11

Section 1

Auto-Zone Basic

If space limitations or total airflow requires it, multiple bypass dampers can be controlled
in parallel. For proper control of the Bypass Damper, the static pressure sensor location is

very important. Refer to Figure 1-3: Locating the Static Pressure Sensor for Bypass
Damper Control below for proper mounting locations.

Preferred Location

If the trunk ducts are properly sized
for minimum pressure drop, the

Fan

location of the static pickup probe is
not particularly critical. It should
ideally be located at right angles to
the airflow in a straight section of the
supply duct approximately ⅔ the
distance of the total length of the
supply duct. Also, the probe should

SA Sensor

Bypass Damper

SPPickup

Supply Air Duct

RASensor

Return Air Duct

SP Sensor

be located not less than 3 duct
diameters downstream and 2 duct
diameters upstream of any elbow or

3D
Min.2DMin.

takeoff.

Less Than Ideal, But
Acceptable

Since the "ideal" location is often

Fan

difficult to find in an installation, a
location in the main trunk where
the tip is not in a "negative
pressure area" (e.g. just
downstream of the inside curve of

Supply Air Duct

SP Sensor

SA Sensor

SPPickup

Bypass Damper

RASensor

Return Air Duct

an elbow) or an area where the
tube opening is directly impacted
by the velocity of the supply air is
acceptable.

Least Desirable, But
Acceptable

If the supply duct comes directly
from the unit and immediately
splits in opposite directions, the
pressure pickup should be located
ahead of the split or as close to it

Supply Air Duct

TubingToBeEqual
LengthAnd Size

Fan

Bypass Damper

SA Sensor

RASensor

Return Air Duct

as possible, even if the bypass
damper(s) are located downstream
of the split.

SPPickups

SP Sensor

Figure 1-3: Locating the Static Pressure Sensor for Bypass Damper Control

1-12 Design Guide

Auto-Zone Basic

Section 1

Step #6 – Sizing Zone Dampers

Use a load program to determine the peak load for each zone. These calculations will be
used in selecting the appropriate zone damper sizes.

A round damper or rectangular damper can be selected depending on the building or job
requirements. If the job requires pressure independent damper control, the damper
selected must be a round damper. Rectangular dampers are not available for pressure

independent control. Please see Table: 1-1 for round damper selection. Please see Table:
1-2 for rectangular damper selection.

Using the maximum acceptable velocity for a branch duct (typically 1000-1500 FPM for
minimal noise), find the smallest damper that will deliver the required CFM as
determined by the load program.

Go to either the Round Damper Selection table (Table: 1-1) or the Rectangular Damper
Selection table (Table: 1-2) depending on your requirements to select the dampers.

Locate the branch velocity used in the duct design program on the left hand column of

either damper sizing chart (Table: 1-1 or Table: 1-2). Move across the chart and find the

damper which will provide the acceptable CFM to meet each zone’s airflow
requirements.

Note: Compare the damper size selected against the duct size to determine if the

next size up or down will provide acceptable performance without requiring a
transition fitting.

Up to two additional dampers may be slaved together for larger zones. See zone wiring
diagram for details. This should be reserved for situations when it is not practical to use a
single large damper.

Design Guide 1-13

Section 1

Note: Dimensions Are

Identical For Round Zone,
Bypass & Slave Dampers

Auto-Zone Basic

Figure 1-4: Round Damper Dimensions

Note: See Table 1-2 for

Available “A” x “B”
Rectangular Damper Sizes

Note: Dimensions Are Identical

For Rectangular Zone, Bypass &
Slave Dampers

Figure 1-5: Rectangular Damper & Kit Dimensions

1-14 Design Guide

Auto-Zone Basic

Section 1

Round Dampers

Round Air Damper Selection

Air Damper Round Duct Size

( Area Ft2 )

Velocity Through Round Air

Damper

(FPM)

750 - Zone
1000 - Zone
1250 - Zone
1500 - Zone

1750 - Bypass Only
2000 - Bypass Only
2250 - Bypass Only

Table 1-1: Round Air Damper Selection

6”

(0.188)

(0.338)

141 254 399 577 788 1031
188 338 532 769 1050 1375
235 423 665 961 1313 1718
282 507 798 1154 1575 2062
329 592 931 1346 1838 2405
376 676 1064 1538 2100 2749
423 761 1197 1730 2363 3094

8”

10”

(0.532)

12”

(0.769)

14”

(1.050)

Volume Through Round Air Damper

(CFM)

16”

(1.375)

Rectangular Dampers

Rectangular Damper Selection

Damper

Height

(B)

Damper

Width

(A)

8”
10”
12”
14”
16”
18”
20”
22”
24”
26”
28”
30”
32”
34”
36”

Table 1-2: Rectangular Damper Selection

Notes: 1.) Zone Dampers Should Be Sized Based On The Required Zone CFM. The Table Above Is

8” 10” 12” 14” 16” 18” 20” 22” 24” 26” 28” 30” 32” 34” 36”

Airflow Through Rectangular Damper

CFM @ 1000 FPM Velocity

410 530 640 740 850 970 1080 1190 1300 1410 1520 1630 1740 1850 1970
510 590 690 800 910 1030 1150 1260 1380 1500 1610 1730 1840 2000 2080
560 650 730 850 970 1090 1210 1330 1460 1580 1700 1820 1940 2060 2190
660 770 880 1030 1180 1330 1480 1630 1760 1910 2060 2210 2360 2510 2640
750 890 1030 1200 1370 1540 1710 1880 2060 2230 2400 2570 2740 2910 3090
770 980 1180 1380 1580 1780 1980 2180 2350 2550 2750 2950 3150 3350 3540
850 1090 1330 1550 1770 1990 2210 2430 2650 2870 3090 3310 3530 3750 3990
930 1210 1480 1730 1980 2230 2480 2730 2950 3200 3450 3700 3950 4200 4440
950 1290 1630 1900 2170 2440 2710 2980 3250 3520 3790 4060 4330 4600 4880

990 1390 1780 2080 2380 2680 2980 3280 3550 3850 4150 4450 4750
1070 1500 1930 2250 2570 2890 3210 3530 3850 4170 4500 4820
1020 1550 2080 2430 2780 3130 3480 3830 4150 4500 4850
1090 1660 2230 2600 2970 3340 3710 4080 4450 4820
1150 1770 2380 2780 3180 3580 3980 4370 4750 NA NA NA NA NA NA
1060 1790 2520 2670 3090 3510 3930 4350 5040

NA NA NA NA NA

NA NA NA NA NA NA

NA NA NA

NA NA NA NA

Calculated Based On 1000 FPM Velocity Through The Rectangular Damper. Zone Damper
Recommended Velocity Is 1000 – 1500 FPM. Select 1000 FPM or Less for Quiet Operation. For Other

Velocities, Use The Following Multipliers To Obtain The Correct CFM: 500 FPM = 0.5, 750 FPM =

0.75, 1250 FPM = 1.25, 1500 FPM = 1.5, 2000 FPM = 2.0, 2250 FPM = 2.25.

2.) Bypass Dampers Should Be Selected for 60% to 70% of the HVAC Units Rated CFM Capacity.

Recommended Bypass Damper Velocity is 1750 – 2250 FPM.

NA NA

Design Guide 1-15

Section 1

Auto-Zone Basic

Pressure Independent Zone Dampers

Pressure Independent operation is only available for round zone dampers. Use the chart
below to set the calibration of the zone damper after installation.

Damper

Size

6” 474

8” 950
10” 1417
12” 2120
14” 2908
16” 3700

Flow Probe “K” Factor =

CFM @ 1” Velocity Pressure

Table 1-3: Pressure Independent Flow Factors

Flow Probe
“K” Factor

Note: K Factors are programmed for each zone so that the correct CFM will be

calculated for the different size air valves.

1-16 Design Guide

Auto-Zone Basic

Section 1

Auxiliary Heat Control
Options

The Auto-Zone Basic Control System offers you a variety of methods to deal with zone
heating requirements. When deciding how to handle zone heating requirements, you
should consider the following:

• Does the rooftop unit have heat?

• Are you using fan-powered boxes?

• Is auxiliary heat used such as baseboard or radiant ceiling panels?

If the zone has some type of heat, you must consider how the heat is to be used. Typical
questions that should be asked:

Q: Should the zone heat be used as a first stage where it will become active before a

heating demand is created at the rooftop unit?

A: This mode is useful if you expect to have both heating and cooling demands at the

same time. The zone will use its own heat and allow the rooftop unit to continue to
provide cooling for other zones. This mode is also useful if the rooftop unit does not
have any heating capabilities.

Q: Is the zone heat only to be used as a second stage where it will be activated only if

the rooftop unit cannot maintain the space temperature such as during very cold
weather?

A: In this mode of operation the rooftop will examine the heating and cooling demands

and try to satisfy all of the zones by switching between heating and cooling as
required. The zone heat will only be activated if the zone temperature falls below a
selected limit.

Q: Should the zone heat be locked out if the rooftop unit is supplying warm air?

A: In many instances, it is desirable to use the rooftop heating whenever possible and

only use zone heat when the rooftop unit is in cooling or vent mode. This often
provides the most cost-effective operation since zone heat is typically electric. This
mode of operation will lockout zone heat if the rooftop is delivering heated air.

Design Guide 1-17

Section 1

Auto-Zone Basic

Relay Expansion Board

The following describes the operation of each of the relays on the optional relay
expansion board. You can choose the appropriate relays for any given application.

Relay #1 - Parallel Fan

If the Zone is in cooling mode or vent mode, the parallel fan can activate any time the
zone temperature drops 0.5°F below the heating setpoint. It de-activates when the
temperature rises above the heating setpoint. The space temperature must be below the
AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be
energized.

Relay #2 - Box Heat

If the zone is in cooling mode or vent mode, the box heat can activate any time the zone
temperature drops 1.5°F below the heating setpoint. It de-activates when the temperature
rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate in the
heating mode when there is hot air being supplied by the air handling unit. This output
was intended to allow zone re-heat while the Zone Manager is satisfying cooling
demands in other zones. The space temperature must be below the AUX HEAT setpoint
in the occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux Heat

In the occupied mode, the aux heat can activate any time the zone temperature is 0.5°F
below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above the
aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating
setpoint with the same deadband values mentioned above. This prevents the zone from
maintaining the same aux heat setpoint at night that it does during the daytime.

This output was intended to allow zone heating to augment the normal heating mode and
also to allow a zone an attempt to satisfy its own heating needs before creating a heating
demand at the Zone Manager.

Relay #4 - Series Fan

The series fan runs any time the main fan is running. This includes occupied and
unoccupied modes. The fan can only start running when the zone damper is closed, so it
determines that the damper is closed before starting the fan.

1-18 Design Guide

Auto-Zone Basic

Index

Section 1

1 inch W.C. ......................................... 10

After-Hours

Overrides........................................... 7

Air

Bypassing.......................................... 6

Air Motion .......................................... 11

Auto-Zone Plus System ........................ 8

AUX HEAT

Setpoint ........................................... 18

Auxiliary Heat

Control Board ................................... 9

Control Options............................... 17

Recommendation .............................. 7

Barometric

Relief Dampers ................................. 7

Baseboard

Heat................................................. 17

Basic System

Design Guide .................................... 8

Diagram............................................. 2

Boards

Relay Expansion ............................. 18

Box Heat ............................................. 18

Building Pressurization......................... 7

Building Zones

Diagram............................................. 9

Bypass

Air ..................................................... 6

Plenum .............................................. 7

Return Air Intake .............................. 7

Bypass Damper

Overview........................................... 3

Sizing .......................................... 8, 11

Bypass Duct Size ................................ 11

Ceiling Diffuser .................................. 11

Central Unit

Sizing .......................................... 8, 10

CFM

Correct ............................................ 16

Maximum........................................ 11

Comfort............................................... 11

Cooling

Partial Load Conditions .................... 5

Cooling Load

Maximum.......................................... 8

Dampers

Slaved.............................................. 13

Design

Duct............................................. 8, 10

Room Air Motion.............................. 8

Zoning............................................... 8

Design Guide ........................................ 8

Diagrams

Basic System..................................... 2

Diffusers

Ceiling............................................. 11

High Induction ............................ 11

Selection...................................... 8, 11

Slot .................................................. 11

Dimensions

Rectangular Damper ....................... 14

Round Damper ................................ 14

Duct Design ........................................ 10

Considerations .................................. 8

Duct Static

High................................................... 6

Duct Static Pressure .............................. 3

Ducted Returns ..................................... 6

Ducts

Undersizing..................................... 10

Ductwork

Damaging.......................................... 6

Economizer

Benefits Of........................................ 6

Recommendation .............................. 5

Equipment

Oversizing......................................... 7

Exhaust

Powered............................................. 7

Exterior Zones....................................... 5

Global Override .................................... 7

Design Guide 1-19

Section 1

Auto-Zone Basic

Heat

Auxiliary ........................................... 7

Baseboard........................................ 17

Supplemental..................................... 9

Heating

Auxiliary ......................................... 17

Difficulties ........................................ 7

Partial Load Conditions .................... 7

Radiant Ceiling Panels.................... 17

Heating Load

Maximum.......................................... 8

Heating Minimum Setpoints................. 7

High Induction Diffusers .................... 11

High Pressure Switch

Manual Reset .................................... 6

Induction Ratio

High................................................. 11

Interior Zones........................................ 5

K Factors............................................. 16

Linear Slot Diffusers........................... 11

Load .................................................... 10

Diversity.......................................... 10

Load Calculation

Program........................................... 11

Load Estimating

Program........................................... 10

Lockout

Low Temp......................................... 5

Low Ambient Termperature Lockout ... 5

Low Supply Air Temperatures.............. 5

Low Temp Lockout............................... 5

Manual Reset

High Pressure Switch........................ 6

Maximum

CFM ................................................ 11

Cooling Load .................................... 8

Duct Velocity.................................. 10

Heating Load..................................... 8

Mechanical Safeties .............................. 5

Mutliple Zones...................................... 8

Negative Pressure Area....................... 12

Noise Levels ......................................... 6

Noise Problems ................................... 10

Operation

Quiet................................................ 10

Override

After-Hours....................................... 7

Conditions......................................... 7

Global................................................ 7

Oversizing

Equipment......................................... 7

Unit ................................................... 6

Overview

Auto-Zone System ............................ 3

Bypass Damper ................................. 3

Zone Controller................................. 3

Zone Manager ................................... 3

Zone Sensor ...................................... 4

Parallel Fan ......................................... 18

Partial Load Conditions ........................ 5

Aggravated........................................ 7

Heating.............................................. 7

Plenum Returns..................................... 6

Powered Exhaust................................... 7

Pressure Dependent............................. 10

Pressure Independent

Flow Factors ................................... 16

Zone Dampers................................. 16

Pressurization

Building ............................................ 7

Problems

Noise ............................................... 10

Program

Load Calculation............................. 11

Load Estimating.............................. 10

Quiet Operation................................... 10

Radiant Ceiling Panels........................ 17

Rectangular Damper

Dimensions ..................................... 14

Selection.......................................... 15

Relay Expansion Board ...................... 18

Relief Dampers

Barometric......................................... 7

Returns

Ducted............................................... 6

Plenum .............................................. 6

Room Air Motion................................ 11

Design ............................................... 8

Round Air Damper

Dimensions ..................................... 14

1-20 Design Guide

Auto-Zone Basic

Section 1

Selection.......................................... 15

Safeties.................................................. 5

Selection

Diffuser ....................................... 8, 11

Rectangular Damper ....................... 15

Room Air Motion............................ 11

Round Air Damper.......................... 15

Series Fan............................................ 18

Boxes............................................... 11

Setpoints

AUX HEAT .................................... 18

Heating Minimum............................. 7

Static Pressure................................... 6

Sizing

Bypass Damper ........................... 8, 11

Central Unit................................. 8, 10

Zone Dampers............................. 8, 13

Slaved

Dampers .......................................... 13

Slot Diffusers ...................................... 11

Linear .............................................. 11

Static Pickup Probe............................. 12

Static Pressure

Setpoint ............................................. 6

Setting ............................................... 7

Static Pressure Sensor........................... 3

Location .......................................... 12

Stratification........................................ 11

Supplemental

Heat................................................... 9

System

Design Guide .................................... 8

Overview........................................... 3

Performance ...................................... 9

Temperatures

Low Supply Air................................. 5

Temperature Lockout

Low Ambient .................................... 5

Undersizing

Ducts ............................................... 10

Units

Oversizing......................................... 6

Velocity

Maximum Acceptable..................... 13

Zone

Comfort............................................. 8

Design ............................................... 5

Diversity............................................ 5

Zone Controller

Overview........................................... 3

Zone Dampers

Pressure Independent ...................... 16

Sizing .......................................... 8, 13

Zone Heating

Auxiliary ......................................... 17

Zone Manager

Overview........................................... 3

Units Per ........................................... 8

Zone Sensor

Overview........................................... 4

Zones

Divided.............................................. 8

Exterior ............................................. 5

External............................................. 9

Interior .............................................. 5

Internal .............................................. 9

Multiple............................................. 8

Number Of ........................................ 8

Overlapping ...................................... 8

Perimeter........................................... 9

Zoning

Design ............................................... 8

Design Guide 1-21

Section 1

Auto-Zone Basic

1-22 Design Guide

Section 2

Table of Contents

Tips Before Beginning Installation..................................1

Zone Manager ..................................................................3

Communications Loop .....................................................8

Communications Loop Wiring Overview........................................................................9

Bypass Dampers ............................................................10

Zone Dampers................................................................13

Zone Controllers ............................................................14

Room Sensors ................................................................................................................21

Supply Air Temperature Sensor ....................................................................................23

Return Air Temperature Sensor.....................................................................................24

Outside Air Temperature Sensor ...................................................................................25

Duct Static Pressure Sensor ...........................................................................................26

Auxiliary Relay Board for Zone Controllers...................28

Zone Controller Auxiliary Relay Board Operation .......................................................29

CommLink IV Interface..................................................30

Basic System Worksheet................................................................................................33

Installation and Wiring

Section 2

Table of Figures

Figure 2-1: System Overview........................................................................................2

Figure 2-2: Typical System Component Locations.......................................................2

Figure 2-3: Zone Manager Dimensions ........................................................................3

Figure 2-4: Zone Manager Component Locations.........................................................4

Figure 2-5: Zone Manager Wiring.................................................................................5

Figure 2-6: Zone Manager Address Switch Setting ......................................................7

Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration .......................9

Figure 2-8: Round and Rectangular Bypass Dampers.................................................10

Figure 2-9: Bypass Damper Wiring.............................................................................12

Figure 2-10: Round and Rectangular Zone Dampers .................................................13

Figure 2-11: Zone Controller Components.................................................................15

Figure 2-12: Zone Controller Wiring..........................................................................17

Figure 2-13: Zone Controller Address Switch Settings..............................................19

Figure 2-14: Slaved Zone Controller Wiring..............................................................20

Figure 2-15: Room Sensor Installation .......................................................................21

Figure 2-16: Room Sensor Wiring..............................................................................22

Figure 2-17: Supply or Return Air Sensor Dimensions and Installation ....................23

Figure 2-18: Outside Air Temperature Sensor Dimensions and Installation..............25

Figure 2-19: Duct Static Pressure Sensor Dimensions and Installation .....................26

Figure 2-20: Static Pressure Sensor Wiring................................................................27

Figure 2-21: Auxiliary Relay Board Layout...............................................................28

Figure 2-22: CommLink IV Interface Communication Wiring..................................30

Figure 2-23: CommLink IV Interface Connections....................................................31

Figure 2-24: CommLink IVJumper Switch Settings ..................................................32

Installation and Wiring

Auto-Zone Basic

Section 2

Tips Before Beginning
Installation

Take a few moments to review the following before beginning installation of the
Auto-Zone Basic Control System.

• Familiarize yourself with all system components and review all documentation.

Pay special attention to “Cautions” and “Warnings” since these may keep you
from experiencing unnecessary problems.

Before installing zone dampers, be sure to tag each damper with its appropriate location.
It is also best to set the zone controller address switches before mounting in drop ceilings.
Use the Basic System Worksheet found in the back of this section or in the Basic Submit­tal Package to list all zone locations and Zone Manager configurations. This will assist
you greatly when setting up the system.

• Be sure to install all wiring according to local, state, and national codes.

• Pay close attention to communication wiring since the most common mistakes are

made in this area. Polarity is the most important rule. Make notes on your wiring dia­grams as to which color wire you will be using on each terminal.

• When in doubt - ask! Contact your local Auto-Zone distributor if you have any ques-

tions. The only dumb questions are the ones you don’t ask.

• Remember - each electronic device contains only one puff of smoke. If you release it,

you have voided the warranty! So please be careful and pay attention.

Installation and Wiring

2-1

Section 2

Auto-Zone Basic

Figure 2-1: System Overview

Typical HVAC Unit

(Packaged or Split System)

Supply Temp Sensor

(Ahead of Bypass Takeoff)

Static Pressure Pickup

(2/3 Of The Way Down Main Duct)

LOCAL COMM LOOP

TWISTED PAIR

WITH SHIELD TO

ZONE CONTROLLER

Above Corridor

( Preferred Location )

Supply Duct

Zone Damper and Control

LOCAL COMM LOOP

TWISTED PAIR WITH

SHIELD TO OTHER

ZONE CONTROLLERS

Zone Sensor

(4-1/2' to 5'; Shoulder Height)

W
A
R
M

N
O

E

R
M

R

A
L

C

O

O

V
R

O
L
E
R

( Over Corridor for Easy Service )

LOCAL COMM LOOP

TWISTED PAIR

WITH SHIELD TO

ZONE CONTROLLER

+

N
FA

1

L
O
O
C

2

L
O
O
C

®

1

T
A
E
H

2

T
A

N

E

E

H

P
O
S

S

E

A

P

S

Y

O

B

L
C
S

N
S
A

IO

P

T

Y

A

B

C
I

+

N
U

M

M
O
C

M
R

A
L

S

A

E

N
O
Z

L
L

E

A

N

=

O

R

Z

A

A

H

E

L
C
A

/C

E

T
I

=

N

B

U

C
A
V
H

=

S

A

C

M

R
A
L

3

R

A

E

T

=

B

N

D

E

2

/

P
E

6

T
S

1

=

L

C

A

#

5

M

I
C

9

E
D

4

=

D

*

8

#

7

0

*

+

+

Diffuser at Perimeter Wall

(Direct Airflow Inward Towards Center of Area)

Bypass Damper

( Locate Where Easily Accessible )

Return Temp Sensor

Duct to Return

(Preferred)

Outdoor Air Sensor

(Mount Away From Direct Sunlight))

(Avoid Mixed Air Area)

Zone Manager

Return Duct

Figure 2-2: Typical System Component Locations

2-2

Installation and Wiring

Auto-Zone Basic

Section 2

Zone Manager

The Zone Manager may be installed in any convenient, protected location. Observe the

recommended environmental limitations for the Zone Manager (see Technical Data sec­tion of product data sheet) when choosing a location. The unit should be mounted with
the display at eye level for easy viewing.

When installing the Zone Manager with display and keypad, you must remove the cover.
Use care not to damage the display while handling and protect the display from physical
damage while removed.

The ribbon cable should be unplugged from the display board which is mounted inside
the front cover. The ribbon cable is keyed to prevent a reverse connection.

Warning: Always remove power before connecting or disconnecting the ribbon

cable which joins the display and keypad to the Zone Manager. Fail­ure to observe this precaution may result in damage to the display or
Zone Manager.

The Zone Manager may be mounted without removing the controller from the enclosure
or mounting plate. The unit is mounted by four (4) screws in the corners. Select the cor­rect screws or other fasteners for the type of mounting material being utilized.

Please see Figure 2-3, Figure 2-4, Figure 2-5, and Figure 2-6 for Zone Manager dimen-

sions, components, wiring, and addressing information.

3.00

Display

11.50

9.25

FRI

Mode

03:48PM

+

08-08-01

Cool

OCCUPIED

ALARMS

NO

1

4

7

*

A

3

B

2

6

C

5

9

D

8

#

0

+

N

FA

1

L

O

O

C

2

L

O

O

C

1

T

EA

H

2

T

EA

H

PEN

O

S

AS

SE

YP

B

LO

C

N

SS

A

TIO

YP

A

B

IC

N

U

M

M

O

C

RM

LA

S

A

NE

ZO

LL

E

A

N

=

ZO

A

AR

H

C

EA

=

B

UNIT/CLE

C

A

V

H

=

S

C

M

R

ALA

TER

=

D

/EN

STEP

=

L

A

#

IM

EC

D

=

*

+

Keypad

+

Figure 2-3: Zone Manager Dimensions

Installation and Wiring

2-3

Section 2

Auto-Zone Basic

Mounting Holes
Typ. Of 4

24 VAC
Power Input

Power LED

Not Used

Real Time
Clock Chip

Comm
LED

Bypass
Damper
Connections

FDBK
GND
Open
Close

HVAC Unit
Connections

(R) Common
Fan
Cool 1
Cool 2
Heat 1
Heat 2

RAM Size
Select
Jumper

24VAC

GND

I2CEXP PORT

D13

D14

D15

R39

R40

BYPASSPDAMPER

TB7

R10

C1

D1

V1

U2

C6

R7

D7

POWER

TB2

REC

FDBK

GND

OPEN

CLOSE

V3

V4

V5

V6

R

FAN

COOL1

COOL2

HEAT1

HEAT2

V7

V8

V9

L1

R18

D9

D11

R26

CX3

U3

R32

R34

C17

U6

K2

K4K3

K5

K7K6

K8

RAM
Chip

Address Switch

(Set To 0 Without
CommLink. Set to 17
With CommLink)

Static Pressure

Real Time
Clock Chip

R2

R1

VR1

R9

C9

D12

Y1

R25

C12

SC1

CX4

R29

R33

R35

CX6

U7

OPEN

CX7

D17

R41

R42

CLOSE

D18

R43

FAN

R44

D19

COOL1

R46

D20

COOL2

D21

R52

HEAT1

D22

R56

HEAT2

D31

R57

VR2

C2

C3

5.11V
ADJUST

Q1

R20

D10

R22

R21

CX5

J01

U5

EWDOG

R36

C18

U8

C21 C20

32K

8K

JO2

U13

D23

D24

D26

D25

D27

SW1

NET

B

32

16

X2

RAM

U10

CX10

RN2

1

CX13

D29

D30

D28

MADE IN U.S.A.

ADD

284

1

PAL

EPROM

Chip

Chip

Sensor - Optional
Modular Connection
Input

CX1

R5

R4

R3

U1

D2

D3

C4 C5

D4

D5

D6

D8

R15

VR3

R13

R23

R24

R61

C19

5.11V
ADJ

YS101722

Rev. 2

EPROM

U11

CX11

1992

SENSOR JACK

PRESSURE

PJ1

R11

R12

C7

R14

R16

R17

C11

R19

C13

R27

R28

R30

R31

C15

R37

R38

Q2

D16

CX9

U9

R45

R47

R48

U12

U14

CX14

CX12

CX15

U15

RS-485

COMM DRIVER

+5V

PU1

C8

PU2

PU3

C14

PU4

PU5

ECONOMIZER

R58

R59

SIG

C16

PU6

EXH/RELIEF

RN1

R49

R55

R60

TB1

GND

ANALOG
INPUTS

+12V

SAT

RAT

OAT

AUX1

AUX2

AUX3

GND

GND

V2

ANALOG
OUTPUTS

GND

C22

T

SH

R

RS-485
Communications
Driver Chip

TB3

EXHAUST
CONTACTS

N.O.

TB4

TB5

Note:

EXP

Keypad & Display

BUSS

Not Shown

P1

COMM

TB8

Static Pressure
Sensor Inputs

+5V
SIG
GND

Analog Inputs
SAT

RAT
OAT
AUX1
AUX2
AUX3
GND

Binary Output

Relief/Exhaust
Fans

Analog Output

0-10 VDC
Economizer

Display &
Keypad
Ribbon Cable
Connector

RS-485
Communications
Loop Connection

T
SH
R

Typical
Pin 1
Indicator

Figure 2-4: Zone Manager Component Locations

2-4

Installation and Wiring

Auto-Zone Basic

Section 2

Bypass

Air Damper

Actuator

Bypass & Slave

Interface Card

BYPASSAND

SLAVEINTERFACE

YS101824

OPEN

CLOSE

FROM ZONE

LD2

LD1

W1

HVAC Unit

W2

24VAC Only

Line

Voltage

TO ACTUATOR

PJ1

TB2

CONTROLLER

PJ2

TB1

R

G
Y1
Y2

GND

OPEN

CLOSE

FDBK

GND

OPEN

CLOSE

24VAC

GND

See Note 1 &2

Splice As

Required

10

Basic Zone Manager

+

NE5090

BYPASS

OPEN

BYPASS

CLOSE

G

FAN

Y1

COOL 1

Y2

COOL 2

W1

HEAT 1

W2

HEAT 2

+

LCD DISPLAY

KEYPAD

1 2 3BA

4 5 6

0*#D

D

D

D

D

D

D

D

24

22

20

18

19

23

21

SW
1

16

B

4

2

NET

32

8

Communications To Zone

Notes:

1.)24 VAC Must Be Connected So
That All Ground Wires Remain
Common.

2.)All Wiring To Be In Accordance With

Local And National Electrical Codes
and Specifications.

3.)All Communication Wiring To Be 18
Ga. Minimum, 2 Conductor Twisted
Pair With Shield. Belden #82760 Or
Equivalent.

24VAC

GND

+

POWER

TB2

+

REC

FDBK

GND

OPEN

CLOSE

FAN

COOL1

COOL2

HEAT1

HEAT2

V3

V4

V5

V6

LO HI

+

5.11V
ADJUST

&

D
17

MADE IN U.S.A.

C 1992

RockerDown

>

ADD

OFF

1

RS-485

Controllers

Static

Pressure

Sensor

C987

Pick-up

SEN

SO
R
JA
C

K

PJ1

75176

RS-485

COMM DRIVER

Static

PRESSURE

+5V

+

Red

Blk

SIG

RIBBON

CABLE

Grn

TB12

GND

ANALOG

INPUTS

+12V

+

SAT

RAT

OAT

AUX1

+

AUX2

AUX3

GND

GND

+

EXHAUST

CONTACTS

N.O.

ANALOG

OUTPUTS

A1

A2

G

EXP
BUSS

R5

R6

C
2

COMM

T

SH

R

Local Loop

TB2

P1

C
1

+

To Relief / Exhaust Fans

RS-485

Communications

To CommLink

When Used

Suppy Air Temp.

Sensor

Return Air Temp.

Sensor

Outdoor Air Temp.

Auxiliary Inputs
( Dry Contacts )

Aux3

Aux2

Forced

Filter

Occupied

Alarm

Mode

Economizer Actuator

Use Extreme Care When Wiring

Economizer Actuators

Never Connect Or Disconnect

Wiring With Power Applied!

Never Apply Power If The

Gnd ( 1 Com ) Terminal On The

Actuator Is Not Connected.

Belimo Actuator Wiring Shown.

Consult Factory For Other
Models Of Economizer Actuators.
Some Actuators Require Isolation
Transformers In Order To Prevent
Damage To The Controller Board.

Sensor

(See Note 4)

Aux1

Economizer

Disable

5U

BELIMO

4Y2

AF24-SR

3Y1

133 IN-LB

2+

1 COM

WARNING!

Figure 2-5: Zone Manager Wiring

Warning: Use extreme care not to damage any of the electronic components

while mounting the enclosure. Mark the holes and then remove the

Zone Manager before drilling. Do not allow metal shavings

to fall onto the circuit boards.

Installation and Wiring

2-5

Section 2

The Zone Manager requires the following electrical connections:

18-Gauge minimum unless otherwise noted.

-24VAC Supply Voltage........................................................................... 2 Conductors

-Communications Loop ...................................... 2 Conductor twisted pair with shield

(Belden #82760 or equivalent)

-Supply Air Temperature Sensor........................................ (24 ga. Min.) 2 Conductors

-Return Air Temperature Sensor ........................................(24 ga. Min.) 2 Conductors

-Outside Air Temperature Sensor.......................................(24 ga. Min.) 2 Conductors

-Supply Static Pressure Sensor ...........................................(24 ga. Min.) 3 Conductors

-Bypass Damper........................................................................................ 4 Conductors

-HVAC Unit Control Wiring.....................................................................R - Common

G - Fan
Y1 - Cool 1
Y2 - Cool 2
W1 - Heat 1
W2 - Heat 2

Tip: After making all electrical connections, you should unplug all terminal blocks

on the Zone Manager until you are ready to begin the checkout procedure. This
may help to prevent damage if wiring errors occur elsewhere in the system dur­ing installation or start-up.

Auto-Zone Basic

2-6

Installation and Wiring

Auto-Zone Basic

BYPASSPDAMPER

FDBK

GND

OPEN

CLOSE

V3

K4K3

V4

V5

V6

K5

TB7

R

FAN

COOL1

COOL2

HEAT1

K7K6

HEAT2

V7

V8

K8

V9

CLOSE

D18

R43

R44

D19

COOL1

R46

D20

COOL2

D21

R52

HEAT1

D22

R56

HEAT2

R57

D31

Section 2

RAM

EPROM

FAN

U10

32K

8K

JO2

RN2

U13

D23

D24

D26

D25

D29

D28

D27

SW1

NET

32

B

16

U11

CX10

CX11

1

CX13

D30

MADEIN U.S.A.

1992

ADD

284

1

U14

U9

R45

R47

R48

U12

CX14

U15

RS-485

COMMDRIVER

CX9

RN1

R49

P1

R55

C22

CX12

CX15

COMM

T

R58

R59

R60

SH

R

TB8

RS-485

Communications

To CommLink

When Used

Local Loop

RS-485

9600 Baud

RS-485

Communications To Zone

Controllers

All Comm Loop Wiring Is

Straight Thru

T

T

SH

R

T

SH

SH

R

R

T

SH

R

These Switches Must Be
In The OFF Position
As Shown

RockerDown

>

Notes:

1.)AllCommunication Wiring To Be
2 Conductor Twisted Pair With
Shield. Use Belden #82760 Or
Equivalent.

2.)It Is Recommended That All
Controllers Address Switches Are
Set Before Installation.

3.)Power To The Zone Manager Must Be
Cycled Before Address Switch
Changes Will Take Affect.

3232BBNET

16

4

8

Address Switch Must Be Set

To Address 0 on Zone Manager Board

As Shown

Basic System Without CommLink

NET

16

4

8

Address Switch Must Be Set

To Address 17 on Zone Manager

Board When CommLink Is Used

ADD

OFF

1

2

These Switches Must Be
In The OFF Position
As Shown

RockerDown

>

ADD

OFF

1

2

Basic System With CommLink

Figure 2-6: Zone Manager Address Switch Setting

NET

NET

B

B

Zone Manager
Address Switch

ADD

2

4

8

16

32

Zone Manager
Address Switch

ADD

2

4

8

16

32

1

1

Caution: Your Auto-Zone Basic Control System will not work properly unless

you set the Address switch correctly. Remember, you must power

down the Zone Manager after changing the address switch in order for
the change to take effect.

Installation and Wiring

2-7

Section 2

Auto-Zone Basic

Communications Loop

The communications network is a two-wire shielded RS-485 loop. The loop is best con-

nected in a daisy chain configuration, meaning the loop is connected from one controller

to another. It is not necessary to sequentially address the zone controllers in relation to
their location on the loop. Cable must be Belden No. 82760 or equivalent.

Tip: Incorrect wiring of the communications loop is the most common mistake made

during installation. Before beginning installation, write down the wire color
used on each terminal connection and consistently maintain that color code. It is
recommended that a continuous wire run be made between devices. Any time a
splice is made in the cable, you increase your chance of problems.

Caution: Make sure when you are inserting wires into the terminal blocks that

strands of wire do not stick out and touch the next terminal. This could
cause a short or erratic operation.

Note: The loop does not have to follow the controller address sequence.

Caution: If comm loop is not installed in conduit, be careful to position the cable

away from high noise devices like fluorescent lights, transformers,
VFDs, etc. Conduit is not required for comm loop wiring unless re­quired by local codes.

2-8

Installation and Wiring

Auto-Zone Basic

Section 2

Communications Loop Wiring Overview

The daisy chain is the best method for running a communications loop since there is only

one starting point and one ending point. See Figure 2-7.

Figure 2-7: Communication Loop Wiring, Daisy-Chain Configuration

Even though the daisy chain configuration is preferred, the star configuration can also be

used. If required, a combination of the two can also be used. Remember, the best comm

loop wiring is the one which utilizes the minimum number of ends while using the short­est wiring path. See Figure 2-6 and Figure 2-13 for controller addressing information.

Installation and Wiring

2-9

Section 2

Auto-Zone Basic

Bypass Dampers

The Bypass Damper can be either round or rectangular. The Round Bypass Damper is
supplied with the Damper Actuator and Bypass Wiring Interface Board factory mounted
in a sheet metal enclosure attached to a Round Air Damper assembly. This Round Bypass
Damper Package is field connected to the appropriate size round duct. Rectangular By­pass Dampers mount directly in the rectangular ductwork using flanged connections field
formed in the rectangular ductwork. A Rectangular Bypass Damper Kit is required to
complete the Rectangular Bypass Damper package. The Rectangular Bypass Damper Kit
is supplied with the Damper Actuator and Bypass Wiring Interface Board factory
mounted in a sheet metal enclosure. This assembly is then field mounted over the Rec­tangular Damper shaft and secured to the ductwork with sheet metal screws.

Figure 2-8: Round and Rectangular Bypass Dampers

Up to two additional Rectangular Bypass or Round Bypass Dampers can be slaved to­gether when it is not practical to use a single large damper. See Figure 2-9. The bypass

damper(s) should be installed as close as possible to the rooftop unit.

Round and Rectangular Bypass Dampers should be securely hung using either wire cra­dles or metal strapping. While the dampers may be hung in any position, avoid sharp
kinks in flexible duct to prevent airflow restrictions. The Round Bypass Dampers are in-

sulated for use in non-conditioned spaces to avoid sweating and to improve energy effi-

ciency.

See Figure 2-2 for a typical bypass damper mounting location. See Figure 2-9 for typical

Bypass Wiring Interface Board wiring instructions.

2-10

Installation and Wiring

Auto-Zone Basic

Section 2

Warning: If sheet metal screws are used to mount the dampers, be certain that

they do not interfere with the movement of the damper blade.

Warning: Never depress the actuator clutch with power applied. Unplug the ac-

tuator cable before depressing the clutch and attempting to rotate the
damper blade. Do not force the damper blade as this can damage the
gears in the damper actuator.

Installation and Wiring

2-11

Section 2

Auto-Zone Basic

BYPASS ACTUATOR #1

(MASTER)

10

MODULAR CABLE

BYPASS ACTUATOR #3 (SLAVE)

(WHEN USED)

1 10 0

NOT USED FOR
THIS APPLICATION

CLOSE

OPEN

TB1

GND

FDBK

CLOSE

OPEN

GND

BYPASS &

SLAVE INTERFACE CARD

PJ2

FROM ZONE

CONTROLLER

TB2

PJ1

TO ACTUATOR

LD2

OPEN

SLAVEINTERFACE

YS101824

LD1

CLOSE

BYPASSAND

BYPASS ACTUATOR #2 (SLAVE)

ZONE MANAGER BOARD

NE5090

REC

K1

OPEN

FDBK

GND

K2

CLOSE

OPEN

CLOSE

V3

V4

NETWORK

T

SH

R

BYPASS &

SLAVE INTERFACE CARD

TO ACTUATOR

BYPASSAND

SLAVEINTERFACE

YS101824

PJ1

GND

OPEN

TB2

CLOSE

OPEN

CLOSE

FROM ZONE

CONTROLLER

PJ2

LD2

LD1

FDBK

TB1

CLOSE

GND

OPEN

MODULAR

CABLE

NOT USED FOR
THIS APPLICATION

BYPASS &

SLAVE INTERFACE CARD

TO ACTUATOR

BYPASSAND

SLAVEINTERFACE

YS101824

PJ1

GND

OPEN

TB2

CLOSE

OPEN

CLOSE

FROM ZONE

CONTROLLER

PJ2

LD2

LD1

FDBK

GND

TB1

OPEN

CLOSE

MODULAR

CABLE

NOT USED FOR
THIS APPLICATION

Figure 2-9: Bypass Damper Wiring

Warning: If the fan system has the capability of producing static pressures

which could damage ductwork, you must provide a manual reset

high pressure limit switch to cut-off the fan system in the event of

high duct static. Do not use your Auto-Zone Basic Con-

trol System as a safety device!

2-12

Installation and Wiring

Auto-Zone Basic

Section 2

Zone Dampers

The Zone Damper can also be either round or rectangular. The Round Zone Damper is
supplied with the damper actuator and Zone Controller factory mounted in a sheet metal
enclosure attached to a Round Air Damper assembly. This Round Zone Damper Package
is field-connected to the appropriate size round duct. Rectangular Zone Dampers
mounted directly in the rectangular ductwork using flanged connections field formed in
the rectangular ductwork. A Rectangular Zone Damper Kit is required to complete the
Rectangular Zone Damper package. The Rectangular Zone Damper Kit is supplied with
the Damper Actuator and Zone Controller factory-mounted in a sheet metal enclosure.
This assembly is then field-mounted over the Rectangular Damper shaft and secured to
the ductwork with sheet metal screws.

Figure 2-10: Round and Rectangular Zone Dampers

Up to two additional Rectangular Zone or Round Zone Dampers can be slaved together
when it is not practical to use a single damper. See Figure 2-14. Generally this is not re-

quired.

Round and Rectangular Zone dampers should be securely hung using either wire cradles
or metal strapping. While the dampers may be hung in any position, avoid sharp kinks in
flexible duct to prevent airflow restrictions. The Round Zone Dampers are insulated for

use in non-conditioned spaces to avoid sweating and to improve energy efficiency.

See Figure 2-2 for typical Round Zone Damper mounting locations. See Figure 2-12 for

Zone Controller wiring instructions.

Installation and Wiring

2-13

Section 2

Auto-Zone Basic

Zone Controllers

The Zone Controllers are mounted in snap-track which is typically located in the control

enclosure on each zone damper. Orient the board in the snap-track so that the actuator,
flow sensor (optional), and auxiliary relay board (optional) cables will reach their respec­tive connectors on the Zone Controller. Carefully press the board into the snap-track to
avoid damaging any of the electronic components on the circuit board. To remove a
board from the snap-track, carefully pull one edge of the snap-track away from the board
with your fingers and remove the board.

Caution: Do not use any tools to pry the board loose. This will damage the

board and/or snap-track.

Warning: When mounting the snap-track, be sure the heads of the screws do not

protrude far enough to touch the bottom of the Zone Controller circuit
board.

Consider serviceability of the location when mounting the Zone Controllers. They should
be easily accessible to facilitate servicing.

Tip: Use small stickers on the ceiling grid or tiles to help future service personnel

locate system components. If you use small stickers from an office supply store,
you can get different colors to code the location of various components.

2-14

Installation and Wiring

Auto-Zone Basic

Section 2

Figure 2-11: Zone Controller Components

Installation and Wiring

2-15

Section 2

The Zone Controller requires the following electrical connections:

24VAC Supply Voltage............................................................................ 2 Conductors

Communications Loop........................................ 2 Conductor twisted pair with shield

(Belden #82760 or equivalent)

Room Temperature Sensor ...................................... 2 Conductors for standard sensors

3 Conductors for sensors with setpoint adjustment

Fan Terminal units / Auxiliary Heat...............2-4 Conductors see wiring diagrams for

(Optional) Aux. Relay board

Tip: After making all electrical connections, it is suggested that all terminal blocks

on the Zone Controller be unplugged until you are ready to begin the checkout
procedure. This may help prevent damage if wiring errors occur elsewhere in the
system during installation or start-up. This is particularly important with the
Zone Controllers since an error on one unit may prevent any of the others from
working until the problem is found and corrected.

Auto-Zone Basic

Warning: Polarity is very important when connecting power to the controllers!

The grounded side of the control transformer must be connected to
the terminal labeled GND on the Zone Controller. If a single trans­former is used to power more than one Zone Controller, you must
connect GND-to-GND and 24VAC-to-24VAC on each zone control­ler. Failure to observe polarity will result in damage to one or more
components in your system.

2-16

Installation and Wiring

Auto-Zone Basic

Section 2

Figure 2-12: Zone Controller Wiring

Installation and Wiring

2-17

Section 2

Set the Zone Controller Address Switch using the addressing instructions in
Figure 2-13.

Caution: Incorrect addressing is the number one cause of communication prob-

lems. Check the addressing carefully. Remember, the Zone Controller

only reads the switch during a power-up. If the address switch is

changed, the unit must be turned OFF and then ON before the new

setting will be recognized.

Note: Ignore any markings or numbers on the switch. Use this chart!

Auto-Zone Basic

2-18

Installation and Wiring

Auto-Zone Basic

Section 2

Figure 2-13: Zone Controller Address Switch Settings

Installation and Wiring

2-19

Section 2

Auto-Zone Basic

EXPANSION

ACTUATOR

PJ2PJ1

ZONE CONTROLLER BOARD

SLAVED- ZONE ACTUATOR #2

(WHEN USED)

ZONE ACTUATOR #1

(MASTER)

10

MODULAR CABLE

SLAVED-ZONE ACTUATOR #1

1 10 0

MODULAR CABLE

BYPASS &

SLAVE INTERFACE CARD

CLOSE

OPEN

TB1

GND

FDBK

CLOSE

OPEN

GND

PJ2

FROM ZONE

CONTROLLER

TB2

PJ1

TO ACTUATOR

LD2

OPEN

YS101824

LD1

CLOSE

BYPASSAND

SLAVEINTERFACE

MODULAR

CABLE

BYPASS &

SLAVE INTERFACE CARD

TO ACTUATOR

BYPASSAND

SLAVEINTERFACE

YS101824

PJ1

GND

OPEN

TB2

CLOSE

OPEN

CLOSE

FROM ZONE

CONTROLLER

PJ2

LD2

LD1

FDBK

GND

TB1

OPEN

CLOSE

NOT USED FOR
THIS APPLICATION

BYPASS &

SLAVE INTERFACE CARD

BYPASSAND

SLAVEINTERFACE

CLOSE

LD1

Figure 2-14: Slaved Zone Controller Wiring

YS101824

OPEN

LD2

TO ACTUATOR

PJ1

TB2

FROM ZONE

CONTROLLER

PJ2

TB1

GND

OPEN

CLOSE

FDBK

GND

OPEN

CLOSE

MODULAR

CABLE

NOT USED FOR
THIS APPLICATION

2-20

Installation and Wiring

Auto-Zone Basic

Section 2

Room Sensors

The Room Sensor uses a patented flush-mount design to isolate the temperature sensing
element from the housing which mounts flush with the wall surface.

Room Sensors should be located on an inside wall away from direct sunlight or heat­producing equipment such as computers, copiers, etc. Such devices can adversely affect
the accuracy of the sensor. Although the sensor eliminates most of the effects of thermal
coupling to the walls, try to avoid walls which retain large amounts of thermal energy
(such as marble or steel). Walls containing either cold or warm air currents should also be
avoided whenever possible. Avoid locating the sensor in dead air areas of a room. This
will result in slow response to temperature changes in the space.

Figure 2-15: Room Sensor Installation

Mount the sensor approximately 50-60 inches from the floor for best results. The Room
Sensor is designed to mount vertically in a standard 2- by 4-inch electrical box. The sen­sor may be mounted directly into the drywall where electrical codes do not require low
voltage wiring to be enclosed in conduit. A template is supplied with the sensor to facili­tate cutting a hole of the correct size.

Tip: Be careful when cutting the hole to make sure the sensor or the plastic bezel of

the sensor will completely cover the opening.

Tip: If sensors must be installed on walls which are solid and cannot be penetrated,

surface-mounted boxes and raceway can be purchased from your local electrical
distributor.

Installation and Wiring

2-21

Section 2

Auto-Zone Basic

Zone Controller

Room Sensor

W

A
R
M
E
R

C
O
O

OVR

L
E

R

TMP

GND

AUX

Connection To AUX
Terminal Required Only
When Sensor Is Specified

AUX

+VS
AUX1

AUX2

GND

TEMP

GND

TB1TB1

++

TB2

With Slide Adjust Option

Figure 2-16: Room Sensor Wiring

Connect the terminal labeled GND on the zone sensor to the terminal labeled GND on the
Zone Controller terminal block for the TEMP SENSOR. Connect the terminal labeled
TMP on the zone sensor to the terminal labeled TEMP on the Zone Controller terminal
block for the TEMP SENSOR. If the zone sensor has a setpoint adjust slider, connect the
sensor terminal labeled AUX to the Zone Controller AUX terminal block labeled AUX1.

2-22

Installation and Wiring

Auto-Zone Basic

Section 2

Supply Air Temperature Sensor

The supply air temperature sensor should be located as close to the rooftop unit dis-

charge as possible for best response. It should also be mounted upstream of the bypass
damper for best results. Locate the sensor in the center of the widest part of the duct. Use
the supplied template and a 5/16" drill to make a hole for the sensor. Install the gasket
over the probe and mount securely to the duct using the supplied sheet metal screws. Be
sure the gasket is compressed to provide an airtight seal. For best accuracy, apply insula­tion on the outside of the duct, over the sensor. This will help prevent thermal gradients
from affecting the sensor.

Leads Are Non-polarized.
Butt Splice Leads To24Gauge
Wire Minimum. Connect Leads

To "AnalogIn"And "Ground"
At Controller.

4.0"

Thread
Together

5-1/2" (OE230)

11-1/2" (OE231)

3/4"

MountingPlate

1/4" HexHead Sheet MetalScrews

Mounting Plate

Gasket

Adhesive Backed Drill Guide
MountingTemplate

Duct Work

Drill 5/16"Hole In Ductwork For Probe

Figure 2-17: Supply or Return Air Sensor Dimensions and Installation

Installation and Wiring

2-23

Section 2

Auto-Zone Basic

Return Air Temperature Sensor

The return air temperature sensor should be located upstream of where the Bypass con-

nects to the return air duct so that the supply air does not affect the reading of the return
air sensor. Avoid locations which will be exposed to extreme outside temperatures. Lo­cate the sensor in the center of the widest part of the duct. Use the supplied template and
a 5/16" drill to make a hole for the sensor. Install the gasket over the probe and mount
securely to the duct using the supplied sheet metal screws. Be sure the gasket is com­pressed to provide an airtight seal. For best accuracy, apply insulation on the outside of
the duct over the sensor. This will help prevent thermal gradients from affecting the sen­sor.

Caution: Do not mount the return air sensor in the mixed air section. This will

cause an error in the reading.

2-24

Installation and Wiring

Auto-Zone Basic

Section 2

Outside Air Temperature Sensor

The outside air sensor must be located where it will not be affected by direct sun or heat

producing equipment. Mounting under the eve of a roof is often a good choice.

Caution: Complaints of inaccurate outside sensor readings are very common and

can almost always be shown to be the result of poor sensor location.

Note: All sensors utilize the same type thermistor sensor element. For troubleshooting

sensors, refer to temperature sensor resetting instructions in section 3 of this
manual.

Gasketed Cover

CAUTION!
See Note3

3.00”

Cover
Mounting
Screw - Typ.

2.30”

2.70”

Closure Plug

CAUTION!
See Note 2

0.21" Dia. x 0.73
Lg. Slot - Typ.

4.50”

3.00”

Front View Side View

Notes:

1.)The Outside Air Sensor Must Be
Mounted In A Vertical Position As
Shown (Sensor Tube Pointing

Water Must Not Be

Down).

Allowed To Stand In Sensor
Tube. Rainwater Will Damage
Sensor.

Sensor Must Be Located
Where It Will Not Be Affected By
Direct Sunlight Or Heat Producing
Equipment. If Possible Mount Under
Roof Eave Or Similar Protected
Location. If Sensor Is Not Located
As Specified, Erroneous Outside Air
Temperature Readings Will Result.

2.25”

1.13”

Sensor Tube

CAUTION!
See Note 1

2.)Unused Conduit Opening(s) Must
Have Closure Plugs Installed And Must
Be Coated with Sealing Compound To
Provide Raintight Seal. Water Can

Damage Sensor!

3.)Gasket Must Be Installed Under Cover
Plate To Provide Raintight Seal.

Rainwater Can Damage Sensor!

4.)All Wiring To Be In Accordance With

Local And National Electrical Codes
And Specifications.

Mounting Tab
& Screw - Typ.

Closure Plug

CAUTION!
See Note 2

Back View

Incorrect

See Note #1

Incorrect

Sensor Mounting

Correct

Postion

Mounting Tab
& Screws - Typ.

Figure 2-18: Outside Air Temperature Sensor Dimensions and Installation

Installation and Wiring

2-25

Section 2

.

Auto-Zone Basic

Duct Static Pressure Sensor

The duct static pressure sensor is designed to be mounted at the controller or on the

ductwork near the pickup tube and may be connected via its modular plug. If the sen­sor is mounted on the ductwork, the modular plug must be cut off and 3-conductor
wire spliced onto the sensor leads. If the trunk ducts are properly sized for minimum
pressure drop, the location of the static pickup probe is not particularly critical. It
should ideally be located at right angles to the airflow in a straight section of the sup­ply duct approximately ⅔ the distance of the total length of the supply duct. Also, the
probe should be located not less than 3 duct diameters downstream and 2 duct diame-

ters upstream of any elbow or takeoff. See Figure 1-3 in section 1 of this manual for

general mounting location information.

1.00"

0.55"

1.95"

0.35"

0.15"

0.60"

0.200" (3/16" Tubing Conn.)

0.125" (1/8" Tubing Conn.)

(-)LO

OE271

S.P. Sensor

2.94"

OUT
GND

0.15" DIA.

UP

IN

1.29"

12.0" APPROX

OUT (Black)
GND (Green)

2.20"

2.50"

IN (Red)

Figure 2-19: Duct Static Pressure Sensor Dimensions and Installation

Caution: Mount the static pressure sensor on a vertical surface with the tube tips

pointing downward. Avoid any kinks or sharp bends in the tubing which
runs from the pickup tube to the sensor.

Warning: The plastic housing on the sensor is electrically conductive. Avoid

contact with any electrical components. It is acceptable to mount the
sensor on grounded sheet metal such as ductwork, electrical panels,
etc.

Warning: Use extreme care when mounting the sensor to avoid damage to the

plastic housing. Do not over-tighten the mounting screws! Do not use
mounting screws which are too large for the holes!

2-26

Installation and Wiring

Auto-Zone Basic

Tip: Having at least 10-20 feet of tubing between the pick-up tube and the pressure

sensor will improve control performance by acting as a “filter” to remove pres­sure fluctuations caused by turbulence in the duct.

Section 2

Figure 2-20: Static Pressure Sensor Wiring

Note: Refer to Figure 1-3 in section 1 of this manual for instructions concerning

proper location of the static pressure sensor.

Installation and Wiring

2-27

Section 2

Auto-Zone Basic

Auxiliary Relay Board for
Zone Controllers

An optional auxiliary relay board is available for the Zone Controllers. This board pro-

vides additional outputs for the following applications:

• Parallel Fan

• Box Heat

• Auxiliary Heat (typically perimeter type)

• Series Fan
The board comes shipped with a modular cable which plugs directly into the Zone Control­ler connector marked “Expansion.” After connecting the board, the system will need to be
powered OFF and then ON for the system to recognize the presence of the relay board.

Figure 2-21: Auxiliary Relay Board Layout

Warning: Relay contacts are rated for 24VAC pilot duty only! Do not apply

voltages higher than 24VAC.

2-28

Installation and Wiring

Auto-Zone Basic

Section 2

Zone Controller Auxiliary Relay Board
Operation

Relay #1 - Parallel Fan

If the zone is in cooling mode or vent mode, the parallel fan relay will activate any time
the zone temperature drops 0.5°F below the heating setpoint. It de-activates when the

temperature rises 0.5°F above the heating setpoint. The space temperature must be below
the AUX HEAT setpoint in the occupied mode before the Parallel Fan relay can be ener­gized.

Relay #2 - Box Heat

If the zone is in cooling mode or vent mode, the box heat relay will activate any time the

zone temperature drops 1.5°F below the heating setpoint. It de-activates when the tem­perature rises to within 1.0°F of the heating setpoint. Box heat is not allowed to activate
in the heating mode when there is hot air being supplied by the air handler. This output
was intended to allow zone re-heat while the Zone Manager is satisfying cooling de­mands in other zones. The space temperature must be below the AUX HEAT setpoint in
the occupied mode before the Box Heat relay can be energized.

Relay #3 - Aux Heat

In the occupied mode, the aux heat relay will activate any time the zone temperature is

0.5°F below the aux heat setpoint. It de-activates when the temperature rises 0.5°F above
the aux heat setpoint. In the unoccupied mode, the aux heat uses the unoccupied heating

setpoint with the same deadband values mentioned above. This prevents the zone from
maintaining the same aux heat setpoint at night that it does during the daytime.

This output was intended to allow zone heating, to augment the normal heating mode,
and also to allow a zone to attempt to satisfy its own heating needs before creating a heat­ing demand at the Zone Manager.

Relay #4 - Series Fan

The series fan relay is energized any time the main fan is running. This includes occu-

pied and unoccupied modes. In the unoccupied mode, the fan can only start when the
zone damper is closed. The controller checks to be sure the damper is closed before start­ing the fan.

Installation and Wiring

2-29

Section 2

Auto-Zone Basic

CommLink IV Interface

The optional CommLink IV is used to transfer communications between controllers on
your control system loops. It can also be used as an interface for connection of a com­puter to your system. The CommLink IV provides communication with any controller on
the control system through a computer that is running Prism software or it can be used to
communicate with most controllers by using only the Zone Manager. For remote com­munications, an IP Module Kit can be installed for LAN and Internet connections or a
Remote Link II can be connected for dial-up connections.

Figure 2-22: CommLink IV Interface Communication Wiring

Locate the CommLink near the computer or modem. The cable connections between the
CommLink and the computer or modem should be kept to less than 25 feet.

The CommLink comes complete with computer and modem cables and a plug-in power
supply. There is an optional IP Module that installs into the CommLink and provides
TCP/IP Internet connection and an optional Remote Link II for dial-up connection or
alarm call-outs. The Zone Manager address switch must be set to 17 when the
CommLink is installed on the Auto-Zone Basic Control System. Also the jumper switch

located on the CommLink circuit board must be set for single loop operation. See Figure
2-23 and Figure 2-24 for details.

2-30

Installation and Wiring

Auto-Zone Basic

Section 2

Figure 2-23: CommLink IV Interface Connections

Installation and Wiring

2-31

Section 2

Auto-Zone Basic

Figure 2-24: CommLink IV Jumper Switch Settings

2-32

Installation and Wiring

Auto-Zone Basic

Section 2

Basic System Worksheet

Project: _______________________ Location ______________________________________________
CommLink Installed: Yes  No  Remote Link Installed: Yes  No  Phone:

_________________
Stages of Cooling ____ Stages of Heating ____ Gas Electric Economizer Yes  No 
Zoning:  Pressure Dependent  Pressure Independent

Zone

Address

1

2

3

4

5

6

7

8

9

10

11

Air
Zone Description or Location

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

Damper

Size

Room

Sensor Type

Relay

Exp. Board

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

12

13

14

15

16

[S=Sensor] [SO=Sensor w/ Override] [SA=Sensor w/ Setpoint adjust] [SOA=Sensor w/ Override & Setpoint adjust]
[AH=Auxiliary Heat] [BH=Box Reheat] [SF=Series Fan Terminal] [PF=Parallel Fan Terminal]

Installation and Wiring

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

S  SO  SA  SOA 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

AH  BH SF  PF 

2-33

Section 2

Index

Auto-Zone Basic

24VAC-to-24VAC.............................. 16

Actuator Cable .................................... 11

Actuator Clutch................................... 11

Address Sequence ................................. 8

Addressing

Checking ......................................... 18

Incorrect .......................................... 18

Zone Controller................................. 1

Zone Manager ................................... 7

Airflow Restrictions

Preventing ................................. 10, 13

AUX

Terminal.......................................... 22

Aux Heat ............................................. 28

AUX HEAT ........................................ 28

AUX1

Terminal.......................................... 22

Auxiliary Heat..................................... 27

Auxiliary Relay Board ........................ 27

Layout Diagram .............................. 27

Belden No. 82760 ................................. 8

Box Heat ....................................... 27, 28

Bypass Damper

Overview......................................... 10

Wiring ............................................. 12

Bypass Dampers

Insulated.......................................... 10

Rectangular ..................................... 10

Round.............................................. 10

Bypass Wiring Interface Board........... 10

Cable

Actuator .......................................... 11

Belden No. 82760 ............................. 8

Splice ................................................ 8

Cables

Auxiliary Relay Board .................... 14

Flow Sensor .................................... 14

Codes

Wiring ............................................... 1

Color Code............................................ 8

CommLink IV

Connections Diagram...................... 30

Jumper Switch Settings................... 31

Overview......................................... 28

Wiring ............................................. 29

Communication Problems

Addressing Incorrectly.................... 18

Communications Loop.......................... 8

Wiring Overview .............................. 9

Component Locations ........................... 2

Components

Damage To...................................... 16

Zone Manager ................................... 4

Conduit.................................................. 8

Configuration

Daisy Chain....................................... 8

Cooling Mode ..................................... 28

Daisy Chain

Configuration .................................... 8

Damper Actuator

Gears, Damaging............................. 11

Overview......................................... 10

Damper Blade ..................................... 11

Forcing ............................................ 11

Dampers

Tagging ............................................. 1

Dial-Up Connections .......................... 29

Dimensions

Zone Manager ................................... 3

Duct Static Pressure Sensor ................ 25

Mounting......................................... 25

Ductwork

Static Pressures ............................... 12

Electrical Connections

Zone Manager ................................... 6

Energy Efficiency

Improving.................................. 10, 13

Environmental Limitations

Zone Manager ................................... 3

Fluorescent Lights................................. 8

2-34

Installation and Wiring

Auto-Zone Basic

Section 2

GND-to-GND ..................................... 16

Heating

Setpoint ........................................... 28

High Pressure Limit Switch

Manual Reset .................................. 12

Incorrect

Wiring ............................................... 8

Installation

Room Sensor................................... 21

SAT or RAT Sensor........................ 23

Zone Manager ................................... 3

Installing

Zone Manager ................................... 3

IP Module Kit ..................................... 29

Kinks................................................... 10

Avoiding ................................... 13, 25

LAN and Internet connections............ 29

Manual Reset

High Pressure Limit Switch............ 12

Metal Shavings ..................................... 5

Metal Strapping............................. 10, 13

Mounting

Duct Static Pressure Sensor ............ 25

Outside Air Sensor.......................... 24

Room Sensor................................... 21

Snap-Track...................................... 14

Supply Air Temperature Sensor ..... 23

Zone Controllers ............................. 14

Zone Manager ................................... 3

Occupied Mode................................... 28

Operation

Auxiliary Relay Board .................... 28

Outside Air Sensor

Installing ......................................... 24

Location .......................................... 24

Mounting......................................... 24

Outside Sensor Readings

Inaccurate........................................ 24

Parallel Fan ................................... 27, 28

Plastic Bezel........................................ 21

Polarity............................................ 1, 16

Prism ................................................... 29

Rectangular Zone Damper

Overview......................................... 13

Remote Link II.................................... 29

Return Air Temperature Sensor

Installing ......................................... 23

Location .......................................... 23

Mounting......................................... 23

Ribbon Cable ........................................ 3

Room Sensor

Installation ...................................... 21

Mounting......................................... 21

Wiring ............................................. 22

Room Sensors

Best Location .................................. 21

Location .......................................... 21

Overview......................................... 21

Round Air Damper.............................. 10

Round Zone Damper

Overview......................................... 13

RS-485 Loop......................................... 8

Safety Device...................................... 12

Sensor

Accuracy ......................................... 21

Series Fan...................................... 27, 28

Setpoints

AUX HEAT .................................... 28

Heating............................................ 28

Sheet Metal Screws............................. 11

Slaved............................................ 10, 13

Slaved Zone Controller Wiring........... 20

Snap-Track

Mounting......................................... 14

Splicing

Cable ................................................. 8

Star Configuration................................. 9

Static Pressure Sensor

Wiring ............................................. 26

Supply Air

Temperature Sensor ........................ 23

Supply Air Temperature Sensor

Location .......................................... 23

Mounting......................................... 23

Sweating

Avoiding ......................................... 13

Improving........................................ 10

System Component

Locations........................................... 2

System Overview

Diagram............................................. 2

Installation and Wiring

2-35

Section 2

Auto-Zone Basic

Tagging

Dampers ............................................ 1

TEMP

Terminal.......................................... 22

TEMP SENSOR.................................. 22

Temperature Sensor

Return Air ....................................... 23

Supply Air....................................... 23

Thermistor Sensor............................... 24

Transformers......................................... 8

Unoccupied Mode............................... 28

Vent Mode .......................................... 28

VFDs ..................................................... 8

Wire

Color Code........................................ 8

Wire Color ............................................ 8

Wire Cradles ................................. 10, 13

Wiring ................................................... 1

Bypass Damper ............................... 12

Codes................................................. 1

CommLink IV................................. 29

Communications Loop...................... 9

Incorrect ............................................ 8

Room Sensor................................... 22

Star Configuration............................. 9

Static Pressure Sensor..................... 26

Zone Controller......................... 17, 20

Zone Manager ................................... 5

Worksheet

Basic System................................... 32

Zone Controller

Address Switch Settings ................. 19

Address Switches.............................. 1

Component Diagram....................... 15

Damage Prevention......................... 16

Electrical Connections .................... 16

Setting Address ............................... 19

Slaved Wiring ................................. 20

Wiring ............................................. 17

Zone Controllers

Mounting......................................... 14

Overview......................................... 14

Zone Damper ...................................... 13

Overview......................................... 13

Zone Manager

Addressing Switch ............................ 7

Board................................................. 4

Dimensions ....................................... 3

Electrical Connections ...................... 6

Environmental Limitations ............... 3

Installation ........................................ 3

Mounting........................................... 3

Ribbon Cable .................................... 3

Wiring ............................................... 5

2-36

Installation and Wiring

Section 3

Table of Contents

LCD/Keypad Operations...................................................1

Main Screen Access.........................................................................................................1

Data Entry Functions .......................................................................................................2

Zone Summary Screen .....................................................2

Individual Zone Status Screens.......................................3

Zone Manager Status Screens ........................................5

Alarm Status Screens......................................................7

Entering Passcodes .........................................................9

Main Menu Operation.......................................................9

Zone Controller Setpoints..............................................10

Zone Manager Setpoints................................................14

Week Schedules.............................................................................................................14

Holidays.........................................................................................................................15

Setting Time & Date......................................................................................................16

Control Setpoints ...........................................................................................................16

Zone Manager Configuration .........................................20

System Overrides...........................................................24

Zone Manager Operations Summary .............................26

Programming

Auto-Zone Basic

Section 3

LCD/Keypad Operations

Main Screen

Vent Mode
03/19/02 03:05pm Tue
Occupied
1 Alarm(s) 3

The Auto-Zone Zone Manager is your direct link into the status and setpoints of any
Zone Controller on your communications loop. With the Zone Manager, you can view
any temperature or output condition and change any setpoint to fine tune the operations
of the total system. All keypad operations are simple and straightforward and use non­cryptic plain English messages.

The remainder of this section will lead you through the system menus and keypad
operation.

Current Polling Address

Main Screen Access

Keypad Layout

A - Summary
B - Status
C - Status
D - Alarms
# - Menu

Programming 3-1

Select the Zone Controller Summary Screen
Select Individual Zone Status Screens
Select the Zone Manager Status Screens
Select the Alarm Status Screens
Select the Main Menu Screen

Section 3

Data Entry Functions

Auto-Zone Basic

A - Abort

Used to exit from screens or from data entry.
Use this key to return to the Main Menu from
any screen in the system.

B - Backup

Use this key to step backwards to previous
screens or setpoints.

C - Clear

If a data entry mistake is made, press this key
to clear the data entry field and start over.

D - Negative

* - Decimal

If entering a setpoint that is negative in value,
press this key for the minus sign.

Use this key as the decimal point when
entering decimal values.

# - Enter

Use this key to close a data entry field and
advance to the next item or screen.

Zone Summary Scr een

To see a summary of all attached Zone Controllers, press the "A" key while the Main
Screen is active. The following screen will appear. Zones are shown in groups of three.
Step to each additional screen by pressing the "#" key. If there are not three units
available for any given screen, the remaining lines on that screen will be blank.

Zone TEMP CLSP HTSP
1 74.2 77.0 74.0
2 73.1 75.0 72.0
3 76.4 75.0 72.0

Zone TEMP CLSP HTSP
4 74.2 77.0 74.0
5 73.1 75.0 72.0
6 76.4 75.0 72.0

etc.

Zone TEMP CLSP HTSP
16 74.2 77.0 74.0

Note: The temperature displayed includes the slide effect offset.

3-2 Programming

Auto-Zone Basic

Section 3

Individual Zone Status
Screens

To see the complete status of any attached Zone Controller, press the "B" key while the
Main Screen is active. The following screens will appear. Step to each additional screen
by pressing the "#" key. Press the "A" key to exit before all status screens have been
viewed. If a zone doesn't respond, the screen will display " *** Missing *** ". If the
zone is currently in the Calibration mode, the screen will display "Calibrating." No
status or setpoints are available during calibration.

Note: The top line of every status screen shows the selected zone address.

Status Screen #1

Zone Number 1
Occupied Mode
Voting Unit

Line 2 -

Line 3 -

Status Screen #2

Zone Number 1
Temperature: 75.4
CSP 75.0 HSP 72.0
Slide Adjust.: 0.0

Line 2 - Current Zone Temperature
Line 3 - Current Cooling Setpoint (CSP) & Heating Setpoint

Line 4 - Optional Sensor Slide Adjust effect on Setpoints

Unoccupied Mode
Occupied Mode
Push-button Override
Force Mode Active!

Voting Unit
Non-Voting Unit

(HSP)

Programming 3-3

Section 3

Status Screen #3

Auto-Zone Basic

Zone Number 1
Damper Pos 20
Minimum Setpt 20
Maximum Setpt 100

Status Screen #4

Zone Number 1
Auxiliary Heat Off
Series Fan On

Line 2 - Current Zone Damper Position
Line 3 - Currently active Minimum Damper/Airflow

Setpoint. Each mode has its own minimum setpoint.
These modes are vent, cooling and heating.

Line 4 - Currently active Maximum Damper/Airflow

Setpoint. This value is user adjustable and is used in

all modes of operation, unlike the Minimum
Damper/Airflow Setpoint.

Line 2 -

Auxiliary Heat Off
Box Heating On
Aux Heating On

Box & Aux Heat On

Line 3 -

Series Fan On

or
Blank Line if Fan is Off

Line 4 -

Parallel Fan On

or
Blank Line if Fan is Off

3-4 Programming

Auto-Zone Basic

Section 3

Zone Manager Status
Screens

To see the Zone Manager status, press the "C" key while the Main Screen is active. The
following screens will appear. Step to each additional screen by pressing the "#" key.
Press the "A" key to exit before all status screens have been viewed.

Status Screen #1

HVAC Status
Supply Air 78.6
Static Press 0.49
Bypass Damper 24%

Line 2 - Current Supply Air Temperature
Line 3 -

Line 4 -

Status Screen #2

HVAC Status
Return Air 75.3
Outdoor Air 70.2
Economizer 20%

Line 2 - Current Return Air Temperature
Line 3 - Current Outdoor Air Temperature
Line 4 - Current Economizer Damper Position if the system is

If the system is configured for VAV operation, this
line shows the current Static Pressure in the duct. It
is displayed in Inches of Water Column.

If the system is configured for VAV operation, this
line shows the current Bypass Damper position
currently required to maintain the displayed amount
of Static Pressure.

configured for Economizer control.

Programming 3-5

Section 3

Status Screen #3

Auto-Zone Basic

HVAC Status
Active Cool Stage: 0
Active Heat Stage: 0
Wetbulb Temp: xxx.x

Status Screen #4

HVAC Status
Mavericks 0
Cool Total 0.0
Heat Total 0.0

Line 2 -

Line 3 -

Line 2 - The currently Active Cooling Stages are displayed on

this line. You can see the first two stages from the
LED display on the front panel. This screen allows
you to view systems with more than two stages of
cooling and see how many are active.

Line 3 - The currently Active Heating Stages are displayed on

this line. The same LED information is available for
heating as described above.

Line 4 -

If the optional Economizer Module has been installed
on your system, this line will show the currently
calculated Wetbulb Temperature.

The Zone Manager knows if any units have had a
four-degree demand for at least one hour. It totals
them up and displays this value as the total number of
Maverick Zones.

As the Zone Manager polls its Zone Controllers, it
totals up the heating and cooling demand so it can
make an HVAC decision.

The Cooling Total is displayed on this line.

Line 4 - The Heating Total, from the zone polling, is

displayed on this line.

3-6 Programming

Auto-Zone Basic

Section 3

Alarm Status Screens

If the last line on the Main Screen displayed one or more active alarms, you can press the
"D" key while on the Main Screen to display a list of detected alarms. Each screen
displays one alarm at a time. If no alarms are present when you press the "D" key, the
message "No Alarms" will be displayed on the alarm screen.

Status Screen #1

Alarm Status

No Alarms

Line 3 -

Possible Alarm Messages that can be displayed, one
at a time, on this line.

Zone Manager Messages

Bad Supply Air Sensor

Static Sensor Alarm
Damper Feedback Fail
Damper Opening Alarm
Damper Closing Alarm
Auxiliary Alarm
COOLING FAILURE!
HEATING FAILURE!
OAT Broadcast Lost

Zone Controller Messages
Missing Zone 1

Zone Damper Fail 1
Bad Zone Sensor 1
Maverick Zone 1

All Zone Controller messages are followed by the
address of the unit that is causing the alarm.

If any alarms are present, the Alarm LED on the
Front Panel will be active, alerting you at a distance
that an alarm is present.

Programming 3-7

Section 3

Alarm Definitions

Auto-Zone Basic

Cooling Failure! or Heating Failure!

Bad Supply Air Sensor or Bad Zone
Sensor

Bypass Feedback Fail

Damper Opening Alarm

Damper Closing Alarm

Static Sensor Alarm

- Once the heating or cooling is activated, the

Supply Air Temperature has 30 minutes to
change by at least 5°F, or the Zone Manager
assumes a mechanical failure has occurred and
generates an alarm.

- The Zone Manager or Zone Controller was

unable to detect the appropriate sensor
installed.

- During calibration the controller does not

receive a signal from the Bypass Damper
Actuator Feedback Pot.

-

The Bypass Damper Actuator does not travel
the full open position on a call to open.

-

The Bypass Damper Actuator does not travel
to its full closed position on a call close.

-

The current static pressure reading has been
above 3.0 inches or below 0.01 inches for more
than 30 seconds.

Missing Zone

Zone Damper Fail

Auxiliary Alarm

Maverick Zone

- The Zone Manager has been out of contact

with a specific zone for 5 consecutive pollings.

-

The zone damper either failed the startup
calibration or it has stopped responding to
commands.

- A contact closure is detected on the AUX2
input

-

The identified zone has exceeded a 4°F heating
or cooling demand for at least 1 hour.

3-8 Programming

Auto-Zone Basic

Section 3

Entering Passcodes

Any time you are prompted to enter a passcode, the following screen will appear. The
actual passcode digits are never displayed. Instead, an "X" is placed on the screen for every
digit entered, as a place holder, to allow you to know which digit you are entering. The
default passcode is "1111" and is programmable to any other four-digit value.

Passcode Request

THIS ACTION REQUIRES
PASSCODE CLEARANCE
Enter Passcode: xxxx

Main Menu Operation

To gain access to the system setpoints and configurations, press "#" while on the Main
Screen to select the Main Menu. There are four selections available on the Main Menu.
Selection of the second item, Manager Setpoints, opens a second menu screen, shown
later in this section. To return to the Main Screen from any other screen, press the "A"
key until the Main Screen appears.

Main Menu

1) Read/Reset Zones

2) Manager Setpoints

3) Configure System

4) System Overrides

For detailed information on each of the Main Menu selections, refer to the appropriate
paragraph heading as noted below.

1) Read/Reset Zones

2) Manager Setpoints

3) Configure System

4) System Overrides

Zone Controller Setpoints
Zone Manager Setpoints
Zone Manager Configuration
System Overrides

Programming 3-9

Section 3

Auto-Zone Basic

Zone Controller Setpoints

You will be prompted to enter the address of the Zone Controller that you want to read or
reset. If you enter a non-existent zone address, the screen will display "*** Missing ***"
and no setpoint screens will be displayed.

Zone Selection Screen

SELECT ZONE
ENTER ADDRESS: 1

Note: The top line always displays the currently selected Zone Controller and the

controller type.

PD ZONE ADDRESS means a Pressure Dependent Box is selected.
PI ZONE ADDRESS means a Pressure Independent Box is selected.

Setpoint Screen #1

PD ZONE ADDRESS 1
OCCUPIED SETPOINTS
Cooling Setpt: 75 F
Heating Setpt: 72 F

Enter the Occupied Heating and Cooling Setpoints on this
screen. The Heating Setpoint should always be two degrees
below the Cooling Setpoint or the Zone Controller will not
accept the new values. The Zone Manager can't prevent the
entry of invalid setpoints. If invalid setpoints are entered, the
previous settings will be retained by the system and displayed
the next time the Zone Setpoints are accessed.

Cooling Setpoint
Heating Setpoint

Minimum Default Maximum

50°F 75°F 90°F
50°F 72°F 90°F

3-10 Programming

Auto-Zone Basic

Section 3

Setpoint Screen #2

PD ZONE ADDRESS 1
UNOCCUPIED SETPOINTS
Cool SetUp...: 10 F
Heat Setback.: -10 F

Enter the Unoccupied Heating and Cooling Setback values on
this screen. The Occupied Cooling Setpoint will be increased
by the Cooling Setback during Unoccupied Mode and the
Heating Setpoint will be decreased by the Heating Setback.

Cool Setback
Heat Setback

Setpoint Screen #3

PD ZONE ADDRESS 1
AuxHeat Setpt: 72 F
Slide Effect.: 3 F

If your Zone Controller has the optional Relay Expansion Board
attached, one of the relays is reserved for an Auxiliary Heating
Relay. Enter that setpoint on the AuxHeat Setpt line. If the
relay board is not installed, this line will not be displayed.

If your Zone Temperature sensor has the optional Setpoint
Adjustment Slide, enter the maximum effect it can have on the
setpoints on the Slide Effect line.

AuxHeat Setpt
Slide Effect

Minimum Default Maximum

0°F 10°F 30°F
0°F -10°F -30°F

Minimum Default Maximum

50°F 72°F 90°F

0°F 3°F 5°F

Note: If slide effect is set to 0°, the push-button override will not function.

Setpoint Screen #4

PD ZONE ADDRESS 1

Max Damper....: 100%

Cool Mode Min.: 5%
Heat Mode Min.: 20%

Programming 3-11

On Pressure Dependent Zones, these setpoints are for damper
position. On Pressure Independent Zones they are for Airflow
(CFM) values, and the text will change to reflect that.

PD Zone Max Damper
PI Zone Max Airflow
PD Zone Cool Mode Min
PI Zone Cool Mode Min
PD Zone Heat Mode Min
PI Zone Heat Mode Min

Minimum Default Maximum

0%

0 CFM

0%

0 CFM

0%

0 CFM

100%

800 CFM

5%

200 CFM

20%

300 CFM

100%

30000 CFM

100%

30000 CFM

100%

30000 CFM

Section 3

Setpoint Screen #5A

Auto-Zone Basic

PD ZONE ADDRESS 1
Vent Mode Min.: 50%
Nite Mode Min.: 100%

On Pressure Dependent Zones, the setpoints displayed are for
damper position.

PD Zone Vent Mode Min 0% 50% 100%
PD Zone Nite Mode Min 0% 100% 100%

Setpoint Screen #5B

PD ZONE ADDRESS 1
Vent Mode xxxxx CFM
Nite Mode xxxxx CFM
CFM @1”WG xxxxx CFM

For Pressure Independent Zones the text changes to display
airflow (CFM) values. On the third line - "CFM@1" WG",
enter the appropriate "K" Flow Factor from Table 1-2 of this
manual.

PI Zone Vent Mode Min 0 CFM 500 CFM 30000 CFM
PI Zone Nite Mode Min 0 CFM 0 CFM 30000 CFM
PI Zone CFM @1" WG 0 CFM 2100 CFM 30000 CFM

Minimum Default Maximum

Minimum Default Maximum

Setpoint Screen #6

PD ZONE ADDRESS 1
Overrides..: Global
Damper Mode: Direct
PRESS (*) TO TOGGLE

The Zone Controller will respond to another zone’s push­button override if it is configured for global overrides. If single
overrides are selected, the zone will only enter override if its
own push-button is pressed.

The normal damper operation is direct acting, which means it
opens in a clockwise direction. If your system opens in a
counter-clockwise direction, select reverse acting mode.

3-12 Programming

Auto-Zone Basic

Section 3

Setpoint Screen #7

PD ZONE ADDRESS 1
Voting Mode: Voting

PRESS (*) TO TOGGLE

Normally, you want a zone to be included in the polling by the
Zone Manager. This allows the demand in that zone to have a
vote in determining the HVAC mode of operation. If you have
a problem zone or an area that you don't want to include in the
voting, select the NonVote mode of operation.

Setpoint Screen #8

PD ZONE ADDRESS 1
Sensor Calibration
Rdg Offset
Zone: 75.4 0.0

Note: The Thermistor Type III Sensors have a 0.4 degree accuracy.

Tip: This calibration offset is also useful as a troubleshooting tool. If you need to

simulate a heating or cooling mode, you can raise or lower the current zone
temperature far enough to put the zone into the desired mode.

If you have a tenant that doesn't agree with the current zone
temperature reading, you can adjust or calibrate the zone
temperature reading.
Enter a positive number if the current reading is too low.
Enter a negative number if the current reading is too high.

Caution: The normal calibration offset should be a fairly small value. If you need

several degrees of offset, there might be a sensor problem or a location
problem.

Programming 3-13

Section 3

Auto-Zone Basic

Zone Manager Setpoints

The Zone Manager Setpoints are kept separate from the Zone Manager Configuration
setpoints since these are the most commonly changed values. Enter the number shown
below for the desired selection. When you are finished, press the "A" key to return to the
Main Menu.

Zone Manager Setpoint Menu

1) Control Setpoints

2) Schedules

3) Holidays

4) Time & Date

Week Schedules

Schedule Start Time

WEEK SCHEDULES
Sunday Start Time
Enter Hrs/Mins: 0
(MILITARY FORMAT)

Schedule Stop Time

WEEK SCHEDULES
Sunday Stop Time
Enter Hrs/Mins: 0
(MILITARY FORMAT)

The screens will step through the Start Time and then the Stop
Time for each day of the week. You can quit at any point in

the process by pressing the "A" key.

All times are in 24-hour format, so 5:00 PM would be entered
as 1700.

If both the Start and Stop Times are ZERO, the schedule is in
a continuous OFF mode.

If both the Start and Stop Times are 2359, the schedule is in a
continuous ON mode.

Note: The second line displays which day of the week is currently being programmed.

This automatically increments as you finish the Stop Time and continue to the
next Start Time screen.

3-14 Programming

Auto-Zone Basic

Section 3

Holidays

Holiday Day Selection

Program Holidays
Holiday # 1
Start Mon/Day: 101
(EX: 101 = Jan. 1)

The screens will step through the eleven possible holidays one
at a time. Line 2 shows which holiday is currently being
programmed.

Remember to combine the month and day into a single four­digit value.

EXAMPLE: 704 = July 4th

Holiday Start/Stop Times

Holiday Schedule

Starting Time: 0
Stopping Time: 0

The eleven holidays all use the same Start and Stop
time which is entered on this screen. It is entered in 24-

hour military format, the same as a regular week
schedule.

1225 = December 25th

Programming 3-15

Section 3

Auto-Zone Basic

Setting Time & Date

The Zone Manager has its own built-in real time clock. Although the times are displayed
on the Main Screen in a standard 12-hour format, they are programmed using the 24-hour
military format. If the Zone Manager was configured to use its own Internal Schedules,
the Occupied/Unoccupied modes are calculated on the basis of the current real time clock
reading.

Programming Time

Program Time/Date
Day (Sunday=0): 2
Enter Hr.(0-23): 14
Enter Min : 53

Day

Hours (Hr)

- Enter the Day of the Week (0 to 6) with
Sunday = 0

- Enter Hours in 24-Hour Military Format
(1700 = 5:00 PM)

Minutes

- Enter the Minutes (0 to 59)

Programming Date

Program Time/Date
Month (1-12): 3
Day (1-31): 19
Year (00-99): 02

Month

Day

Year

- Enter the Month (1 to 12)

- Enter the Day of the Month (1 to 31)

- Enter the current Year with two digits (00
to 99)

Daylight Savings Adjustments

Daylight Savings
Adjustments Enabled

Press (*) To Toggle

If your area of the country requires Daylight Savings changes,
the Zone Manager can automatically make the adjustment for
you. This used to be the first Sunday in April and the second
Sunday in October. However, the U.S. government has now
decided to arbitrarily change these dates from time to time. So
we recommend that you disable these automatic adjustments
by pressing the "*" key to select Adjustments Disabled and
make the adjustments yourself each year.

3-16 Programming

Auto-Zone Basic

Section 3

Control Setpoints

Setpoint Screen #1

Manager Setpoints
Static Press: 0.5”

If you have configured for variable HVAC type, this screen
will be displayed to allow you to enter the controlling Static
Pressure Setpoint.

Static Press

Setpoint Screen #2

Manager Setpoints
Cool Lockout: 50
Heat1 Lockout: 65
Heat2 Lockout: 45

Enter the Mechanical Cooling and Heating Lockouts on this
page. There are two heating lockouts. Heat1 Lockout is for
Stage #1 only, and Heat2 Lockout is for Stages #2 and up.
This allows energy conservation during Spring and Fall
conditions when a single stage of heating could handle the
load.

Cool Lockout
Heat1 Lockout
Heat2 Lockout

Minimum Default Maximum

0.1" 0.5" 2.0"

Minimum Default Maximum

-30°F -30°F 80°F
30°F 65°F 99°F
30°F 45°F 99°F

Programming 3-17

Section 3

Setpoint Screen #3

Auto-Zone Basic

Cool Staging: 4 Min
Min Cool Off: 4 Min
Heat Staging: 4 Min
Min Heat Off: 4 Min

The heating and cooling stages must have been off for a
minimum amount of time before they can be activated or re­activated. As each additional stage of heating or cooling is
added, a minimum Staging Delay period must be satisfied
between each additional stage required.

Cool Staging 1 Min 4 Min 30 Min
Min Cool Off 1 Min 4 Min 30 Min
Heat Staging 1 Min 4 Min 30 Min
Min Heat Off 1 Min 4 Min 30 Min

Setpoint Screen #4

Manager Setpoints
Heat/Cool Changeover

Interval....: 15 Min

If the Zone Manager needs to change HVAC modes
between heating and cooling, a Changeover Delay time
must be satisfied first. This prevents "chasing" due to
alternate hot and cold air always being supplied to the
zones after short intervals.

Interval 1 Min 10 Min 30 Min

Minimum Default Maximum

Minimum Default Maximum

Setpoint Screen #5

Economizer Setpoints
Closed Volts: 0.0
Opened Volts: 10.0

3-18 Programming

If the Zone Manager has been configured for Economizer
Control, this screen will appear. You can set the voltages

required to open and closed the damper. Some actuators use a
2-10 VDC signal instead of 0-10 VDC.

If the system is not configured for Economizer Control, no
economizer setpoint screens will appear.

Closed Volts 0.0 VDC 0.0 VDC 10.0 VDC
Opened Volts 0.0 VDC 10.0 VDC 10.0 VDC

Minimum Default Maximum

Auto-Zone Basic

Section 3

Setpoint Screen #6

Economizer Setpoints
Econo Enable: 50
Supply Setpt: 50
Min Econo % : 20%

The Econo Enable setpoint is the outdoor air or wetbulb
temperature that enables the Economizer to open past its
minimum position setpoint to control supply air temperature.

The Supply Setpt is the supply air temperature the Economizer
tries to maintain.

The Min Econo % is the position the economizer holds during
occupied mode when it is not enabled for operation due to
outdoor air or wetbulb temperature.

Econo Enable
Supply Setpt
Min Econo % 0% 20% 100%

Setpoint Screen #7

Economizer Setpoints
Economizer Interval

Seconds.....: 50.0

During Economizer control, the Economizer damper is
allowed to move open or closed, as required at a rate
controlled by this value. Use this setpoint to speed up or slow
down the operation of your economizer. The larger the
number, the slower the damper will move.

Minimum Default Maximum

-30°F 50°F 99°F
45°F 50°F 80°F

Interval .1 50 90.0

Setpoint Screen #8

Sensor Rdg Offset
SAT.: 82.9 0.0
RAT.: 77.2 0.0
OAT.: 70.2 0.0

As described in the Zone Controller section, the Thermistor
Type III sensor readings can be calibrated. The Outdoor Air
Calibration Offset only applies to the Zone Manager that has
the sensor installed. It has no effect on the global broadcast
value of outdoor air.

Supply Sensor SAT
Return Sensor RAT
Outdoor Sensor OAT

Minimum Default Maximum

Minimum Default Maximum

-100.0°F 0.0°F +100.0°F

-100.0°F 0.0°F +100.0°F

-100.0°F 0.0°F +100.0°F

Programming 3-19

Section 3

Auto-Zone Basic

Zone Manager
Configuration

Normally, the configuration setpoints need to be entered only one time. For this reason,
they occupy their own menu location and need not be addressed during normal setpoint
read and reset operations. To access the configuration setpoints, press the "3" key while
on the Main Menu screen.

Note: On initial power up, the system must be configured before it can be successfully

operated.

Configuration Screen #1

Last Zone Addr: 1
First Zone Addr: 1
Cooling Stages: 1
Heating Stages: 1

Caution: The zones should be consecutively addressed with no skipped address

locations. If an address is skipped, the Zone Manager will presume there
is a missing zone, and an alarm will occur.

The Zone Manager needs to know the address range of the
attached Zone Controllers to be polled. Enter the addresses of
the first and last zones here.

The quantity of cooling and heating stages is also entered on
this screen.

Last Zone Addr 1 1 16
First Zone Addr 1 1 16
Cooling Stages 0 1 6
Heating Stages 0 1 6

Minimum Default Maximum

3-20 Programming

Auto-Zone Basic

Section 3

Configuration Screen #2

Heat Type.: Electric
Fan Mode.: Constant

PRESS (*) TO TOGGLE

The Zone Manager can control electric or gas heating. Each
type of heat has its own protection limits built into the Zone
Manager software.

The Zone Manager can also operate the fan in one of two
modes:

Constant (Continuous) running during occupied hours.
Cycle with heating or cooling during occupied hours.
The fan always cycles with heating or cooling during

unoccupied hours.

Configuration Screen #3

Economizer: Enabled

PRESS (*) TO TOGGLE

The Zone Manager has the ability to control the Economizer
operation. To initiate Economizer operation, select Enabled.
To toggle between the two Economizer modes, press the "*"
key.

Configuration Screen #4

HVAC Type: Variable

PRESS (*) TO TOGGLE

The Zone Manager normally reads the duct static pressure
and controls it via the bypass damper. If your system doesn't
require static pressure control, select the Constant mode of
operation. To toggle between the two modes, press the "*"
key.

Programming 3-21

Section 3

Configuration Screen #5

Auto-Zone Basic

Bypass Act: Direct

PRESS (*) TO TOGGLE

The Zone Manager Bypass Damper normally opens in a
clockwise direction. If your bypass damper opens in a counter­clockwise direction, select reverse acting instead of direct
acting operation. To toggle between the two modes, press the
"*" key.

Configuration Screen #6

Zone Manager
Uses Schedule #: 0
0 = Internal Clock
1-8 = External Clock

The Zone Manager normally uses its own real-time clock and
an internal week schedule to determine the Occupied/
Unoccupied mode of operation. The Zone Manager does have
the ability to use a global broadcast from another scheduling
device on the communications loop if a more powerful schedule
is required. If an external schedule is used, the range of
schedule numbers is 1 to 8.

Configuration Screen #7

Press (*) To Force
Recalibration Of The
Static Press. Sensor
<#> To Skip This...

The Zone Manager only calibrates the static pressure sensor
one time. That occurs on the initial powerup, so it is vital that
the sensor be attached before the system is ever powered up. If
you weren't able to do this or accidentally activated the system
before the sensor was available, you can force it to restart and
calibrate the static pressure sensor by pressing the "*" key. If
you don't need to re-calibrate, simply press the "#" key to skip
over this item.

3-22 Programming

Auto-Zone Basic

Section 3

Configuration Screen #8

Enter New Passcode
CODE: xxxx
[Must Be 4 Digits]
Press <A> To Skip!

As mentioned earlier, the default passcode is "1111". This
code must be entered before any configuration or setpoint
changes can occur. If you would like to change this default
passcode, enter four digits on this screen. The value entered
must be between 1000 and 9999 to be a valid code. Values
from 0000 to 0999 will be rejected and the last valid code will
be retained.

Caution: If you forget your passcode, you WILL BE locked out of your system!

Tip: The BackDoor Passcode that will always get you into the system is "9288." This

passcode should not be given to the casual users of your system.

Programming 3-23

Section 3

Auto-Zone Basic

System Overrides

The Zone Manager provides some user-selectable override modes. This allows you to
troubleshoot the system or set up temporary conditions for those situations when normal
operation of the system is not required.

Override Screen #1

0) AUTO (Time Clock)

1) FORCE Occupied

2) FORCE Unoccupied

3) FAN ONLY [Mode 0]

The Zone Manager defaults to the Auto mode of operation when
first powered up. Any force modes entered will be retained in
non-volatile memory. The unit will resume the force mode of
operation any time the power is cycled.

-

0) Auto

1) Occupied

2) Night

3) Fan Only

Use internal schedules for Day/Night
Mode

-

Forced to Continuous Day or Occupied
Mode

-

Forced to Continuous Night or Unoccupied
Mode. If the Forced Occupied Binary Input
Contact is closed, this mode will override it
to OFF. Use the Auto mode programmed
for continuous Unoccupied operation if you
want to use the Forced Occupied Binary
Input Contact.

This is the mode that is active whenever

you see the Purge Cycle message being
displayed. It disables any heating or cooling
and forces all the boxes to move their
dampers to the full 100 percent open
position. You can use this mode any time
you want to manually purge your building.

3-24 Programming

Auto-Zone Basic

Section 3

Override Screen #2

ZONE FORCE MODES
Force to MINIMUM 0
Force to MAXIMUM 0
[0= Normal 1=Force]

The Zone Controller Dampers can all be forced at the same
time to their Minimum or Maximum Damper/Airflow
Setpoints. On Pressure Independent systems, this feature is
useful during air balance operations.

Enter a "1" next to the desired force mode to make it active.
Enter "0" to disable the force mode.

Programming 3-25

Section 3

Auto-Zone Basic

Zone Manager Operations Summary

1) Read/Reset Zones

2) Manager Setpoints

3) Configure System

4) System Overrides

Main Screen

Vent Mode
06/05/96 08:05am Wed
Occupied
1 Alarm(s) 3

Main Menu Screen

Press “#” Key

Zone Summary Screens

Press “A” Key

Zone TEMP CLSP HTSP
1 74.2 77.0 74.0
2 73.1 75.0 72.0
3 76.4 75.0 72.0

Zone Status Screens

Press “B” Key

Zone Manager Status Screen

Press “C” Key

HVAC Status
Supply Air 56.4
Static Press. 0.49"
Bypass Damper 24%

Alarm Status Screen

Press “D” Key

Control Setpoints Screen

Press “1” Key

Manager Setpoints
Static Press: 0.50”

Zone Number 1
Occupied Mode
Voting Unit

Alarm Status

No Alarms

Schedules Screen

Press “2” Key

WEEK SCHEDULES
Sunday Start Time
Enter Hrs/Mins: 0
(MILITARY FORMAT)

Time & Date Screen

Press “4” Key

Program Time/Date
Day (Sunday=0): 3
Enter Hr. (0-23): 9
Enter Min. : 25

Zone Manager Menu Screen

Press “2” Key

1) Control Setpoints

2) Schedules

3) Holidays

4) Time & Date

Holidays Screen

Press “3” Key

Program Holidays
Holiday # 1
Start Mon/Day: 0
(EX: 101 = Jan. 1)

3-26 Programming

Auto-Zone Basic

Index

Section 3

"K" Flow Factor.................................. 12

# - Enter Button..................................... 2

# - Menu Button.................................... 1

# Key................................................. 2, 9

* - Decimal Button................................ 2

1111....................................................... 9

24-Hour Format .................................. 14

A - Abort Button................................... 2

A - Summary Button............................. 1

A Key.................................................... 2

Active Cooling Stages .......................... 6

Active Heating Stages........................... 6

Address Range.................................... 20

Airflow (CFM) Setpoint ..................... 11

Airflow (CFM) Values........................ 12

Alarm

Definitions ........................................8

Status Screens ................................... 7

Alarm LED............................................ 7

Auto Mode.......................................... 24

Aux Heating On.................................... 4

AuxHeat Setpt..................................... 11

Auxiliary Alarm................................ 7, 8

Auxiliary Heat Off................................ 4

Auxiliary Heating Relay..................... 11

B - Backup Button ................................ 2

B - Status Button................................... 1

B Key.................................................... 3

Back Door Passcode ........................... 23

Bad Supply Air Sensor .....................7, 8

Bad Zone Sensor............................... 7, 8

Box & Aux Heat On ............................. 4

Box Heating On .................................... 4

Buttons

# - Enter ............................................2

# - Menu............................................ 1

* - Decimal........................................ 2

A - Abort........................................... 2

A - Summary..................................... 1

B - Backup ........................................ 2

B - Status........................................... 1

C - Clear............................................ 2

C - Status........................................... 1

D - Alarms......................................... 1

D - Negative...................................... 2

Bypass Damper

Direct Acting................................... 22

Reverse Acting................................ 22

Bypass Damper Position....................... 5

Bypass Feedback Fail ........................... 8

C - Clear Button.................................... 2

C - Status Button................................... 1

C Key.................................................... 5

Calibrating ............................................ 3

Calibration Offset ...............................13

CFM @1”WG xxxxx CFM................. 12

Changeover Delay Time..................... 18

Closed Volts........................................ 18

Configuration

Internal Week Schedule.................. 22

Real-Time Clock............................. 22

Configure System.................................. 9

Control Setpoints .......................... 14, 17

Zone Manager................................. 14

Cool Lockout ...................................... 17

Cool Mode Min................................... 11

Cool SetUp.......................................... 11

Cool Staging .......................................18

Cooling.................................................. 4

Cooling Failure ..................................... 8

COOLING FAILURE........................... 7

Cooling Setback.................................. 11

Cooling Setpoint ................................. 10

Cooling Setpt ...................................... 10

Cooling Stages.................................... 20

Cooling Total........................................ 6

CSP ....................................................... 3

Current Cooling Setpoint...................... 3

Current Zone Temperature ................... 3

D - Alarms Button................................. 1

D – Negative Button ............................ 2

D Key.................................................... 7

Damper Closing Alarm..................... 7, 8

Damper Feedback Fail.......................... 7

Programming 3-27

Section 3

Auto-Zone Basic

Damper Mode: Direct......................... 12

Damper Opening Alarm.................... 7, 8

Damper Position Setpoint............. 11, 12

Damper Positions................................ 12

Data Entry Functions ............................ 2

Daylight Savings................................. 16

Default passcode................................... 9

Direct Acting

Bypass Damper............................... 22

Damper Position.............................. 12

Duct Static Pressure............................ 21

Econo Enable Setpoint........................ 19

Economizer Damper Position............... 5

Economizer Interval............................ 19

Economizer Operation

Zone Manager................................. 21

Economizer Setpoints ......................... 18

Electric Heat .......................................21

Entering Passcodes ............................... 9

Fan Mode

Continuous...................................... 21

Cycle............................................... 21

FAN ONLY ........................................ 24

Fan Operation

Unoccupied Hours .......................... 21

First Zone Addr................................... 20

Force Mode Active ............................... 3

Force Modes .......................................24

FORCE Occupied ............................... 24

FORCE Unoccupied ........................... 24

Gas Heat.............................................. 21

Global Broadcast................................. 22

Global Overrides................................. 12

Heat

Electric............................................ 21

Gas .................................................. 21

Heat Mode Min................................... 11

Heat Staging........................................ 18

Heat/Cool Changeover........................ 18

Heat1 Lockout..................................... 17

Heat2 Lockout..................................... 17

Heating.................................................. 4

Heating Failure ..................................... 8

HEATING FAILURE!.......................... 7

Heating Lockout .................................17

Heating Setback.................................. 11

Heating Setpoint .............................3, 10

Heating Setpt....................................... 10

Heating Stages .................................... 20

Heating Total ........................................ 6

Holiday Start/Stop Times.................... 15

Holidays

Zone Manager........................... 14, 15

HSP....................................................... 3

Inches of Water..................................... 5

Internal Week Schedule...................... 22

Invalid Setpoints................................. 10

K Flow Factor..................................... 12

Keypad Layout...................................... 1

Keypad Operations ...............................1

Keys

# ....................................................... 9

# - Enter ............................................2

# - Menu............................................ 1

# - Next Screen .................................2

* - Decimal........................................ 2

A ....................................................... 2

A - Abort........................................... 2

A - Summary..................................... 1

B ....................................................... 3

B - Backup ........................................ 2

B - Status........................................... 1

C ....................................................... 5

C - Clear............................................ 2

C - Status........................................... 1

C - Zone Manager Status .................. 5

D - Alarm.......................................... 7

D - Alarms......................................... 1

D - Negative...................................... 2

Last Zone Addr................................... 20

LCD Operations.................................... 1

Location Problem................................ 13

Main Menu

Operation ..........................................9

Main Screen.......................................... 1

Manager Setpoints ................................ 9

Maverick Zone.................................. 7, 8

Maverick Zones..................................... 6

Max Damper ....................................... 11

Maximum Airflow

Setpoints.......................................... 25

3-28 Programming

Auto-Zone Basic

Section 3

Maximum Damper

Setpoints.......................................... 25

Maximum Damper/Airflow Setpoint.... 4

Mechanical Cooling Lockout.............. 17

MILITARY FORMAT ....................... 14

Min Cool Off....................................... 18

Min Econo % ...................................... 19

Min Heat Off....................................... 18

Minimum Airflow

Setpoints.......................................... 25

Minimum Damper Setpoints............... 25

Minimum Damper/Airflow Setpoint..... 4

Missing............................................ 3, 10

Missing Zone .................................... 7, 8

Caution............................................ 20

New Passcode ..................................... 23

Night Mode......................................... 24

Nite Mode Min.................................... 12

Nite Mode xxxxx CFM....................... 12

No Alarms............................................. 7

NonVote Mode.................................... 13

Non-Voting Unit................................... 3

OAT Broadcast Lost............................. 7

Occupied Heating and

Cooling Setpoints............................ 10

Occupied Mode..................................... 3

Opened Volts ...................................... 18

Outdoor Air Calibration Offset........... 19

Outdoor Air Temperature ..................... 5

Outdoor Sensor ................................... 19

Overrides....................................... 12, 24

Overrides..: Global.............................. 12

Parallel Fan Off..................................... 4

Parallel Fan On ..................................... 4

Passcode

Back Door....................................... 23

Passcode Request.................................. 9

Passcodes .............................................. 9

PD ZONE ADDRESS......................... 10

PD Zone Cool Mode Min ................... 11

PD Zone Heat Mode Min.................... 11

PD Zone Max Damper........................ 11

PD Zone Nite Mode Min .................... 12

PD Zone Vent Mode Min ................... 12

PI ZONE ADDRESS.......................... 10

PI Zone CFM @1" WG ...................... 12

PI Zone Cool Mode Min..................... 11

PI Zone Heat Mode Min..................... 11

PI Zone Max Airflow.......................... 11

PI Zone Nite Mode Min...................... 12

PI Zone Vent Mode Min..................... 12

Polling Mode....................................... 13

Polling Range...................................... 20

Pressure Dependent Box..................... 10

Pressure Independent Box .................. 10

Programming

Day.................................................. 16

Hours............................................... 16

Minutes ........................................... 16

Month.............................................. 16

Year................................................. 16

Programming Date.............................. 16

Programming Time............................. 16

Push-button Override............................ 3

Push-Button Override

Won't Work..................................... 11

Read/Reset Zones .................................9

Real Time Clock................................. 16

Real-Time Clock

Configuration.................................. 22

Relay Expansion Board ......................11

Return Air Temperature........................ 5

Return Sensor...................................... 19

Reverse Acting

Bypass Damper............................... 22

Damper Position.............................. 12

Schedules

Zone Manager................................. 14

Screens

Zone Selection ................................ 10

Sensor Calibration............................... 13

Sensor Problem................................... 13

Sensor Slide Adjust............................... 3

Series Fan Off....................................... 4

Series Fan On........................................ 4

Setpoint

Airflow (CFM)................................ 11

Cooling............................................ 10

Heating............................................ 10

Setpoint Adjustment Slide.................. 11

Programming 3-29

Section 3

Auto-Zone Basic

Setpoints

Adjustment Slide............................. 11

AuxHeat.......................................... 11

Cooling.............................................. 3

Damper Position........................ 11, 12

Heating.............................................. 3

Invalid............................................. 10

Maximum Airflow.......................... 25

Maximum Damper.......................... 25

Maximum Damper/Airflow.............. 4

Minimum Airflow........................... 25

Minimum Damper........................... 25

Minimum Damper/Airflow............... 4

Occupied Heating and Cooling....... 10

Static Pressure................................. 17

Zone Controller............................... 10

Zone Manager................................. 14

Setting Time & Date........................... 16

Single Overrides ................................. 12

Slide Effect.......................................... 11

Staging Delay Period .......................... 18

Start Time............................................ 14

Static Press.......................................... 17

Static Pressure....................................... 5

Static Pressure Sensor

Re-Calibrate.................................... 22

Static Pressure Setpoint ...................... 17

Static Sensor Alarm.......................... 7, 8

Status

Zone Manager................................... 5

Status Screens

Alarm ................................................ 7

Stop Time............................................ 14

Summary

Zone Controllers ............................... 2

Supply Air Temperature ....................... 5

Supply Sensor ..................................... 19

Supply Setpt........................................ 19

System

Locked Out...................................... 23

System Overrides............................ 9, 24

Thermistor Type III Sensors............... 13

Time & Date

Setting............................................. 16

Zone Manager................................. 14

Unoccupied Heating and Cooling

Setback............................................ 11

Unoccupied Hours

Fan Operation .................................21

Unoccupied Mode................................. 3

Vent....................................................... 4

Vent Mode Min................................... 12

Vent Mode xxxxx CFM...................... 12

Voting Mode....................................... 13

Voting Unit ........................................... 3

Week Schedules

Zone Manager................................. 14

Wetbulb Temperature ........................... 6

Zone CLSP............................................ 2

Zone Controller............................. 1, 3, 8

Setpoints...................................... 9, 10

Zone Controller Alarms........................ 7

Zone Controller Dampers

Forced ............................................. 25

Zone Controllers

Summary........................................... 2

Zone Damper Fail............................. 7, 8

Zone Damper Position .......................... 4

Zone HTSP............................................ 2

Zone Manager

Configuration.............................. 9, 20

Control Setpoints ............................ 14

Economizer Operation.................... 21

Holidays.................................... 14, 15

Operations......................................... 1

Operations Summary ...................... 26

Schedules ........................................ 14

Setpoints...................................... 9, 14

Status Screens ................................... 5

Time & Date ................................... 14

Week Schedules.............................. 14

Zone Manager Alarms .......................... 7

Zone Selection Screen ........................ 10

Zone Status Screens.............................. 3

Zone TEMP........................................... 2

Zones

Read/Reset ........................................ 9

ZoneTemperature Reading.................. 13

3-30 Programming

Auto-Zone Basic

Notes

Section 3

Programming 3-31

Section 3

Notes

Auto-Zone Basic

3-32 Programming